Frymaster PERFORMANCE PRO 45, PERFORMANCE PRO 35 User Manual

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Gas Fryers Models 35 & 45

Performance Pro Series

Service and Parts Manual

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

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

MARCH 2011

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

NOTICE

This appliance is intended for professional use only and is to be operated by qualiﬁ ed personnel only. A Frymaster/DEAN Factory Authorized Service Center (FASC) or other qualiﬁ ed professional should perform installation, maintenance, and repairs. Installation, maintenance, or repairs by unqualiﬁ ed personnel may void the manufacturer’s warranty.

NOTICE

This equipment must be installed in accordance with the appropriate national and local codes of the country and/or region in which the appliance is installed.

NOTICE TO U.S. CUSTOMERS

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

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

NOTICE TO OWNERS OF UNITS EQUIPPED WITH COMPUTERS

U.S.

This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions:

1) This device may not cause harmful interference, and 2) This device must accept any interference received, including interference that may cause undesired operation. While this device is a veriﬁ ed Class A device, it has been shown to meet the Class B limits.

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

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

DANGER

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

DANGER

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

DANGER

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

DANGER

Do not store or use gasoline or other ﬂ ammable liquids or vapors in the vicinity of this or any other ap- pliance.

DANGER

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

DANGER

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

WARNING

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

PERFORMANCE PRO SERIES GAS FRYERS MODELS 35 & 45

Table of Contents

CHAPTER 1: Service Procedures

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

1.1.1 Pilot Ignition ..............................................................................................................................1-1

1.1.2 Electronic Ignition .....................................................................................................................1-1

1.1.3 Controller Options .....................................................................................................................1-2

1.1.4 Thermostats and Temperature Probes .......................................................................................1-2

1.2 Moving the Fryer for Servicing ...........................................................................................................1-2

1.3 Diagnostic Procedures .........................................................................................................................1-3

1.3.1 Cleaning the Gas Valve Vent Tube ............................................................................................1-3

1.3.2 Checking the Burner Manifold Gas Pressure ............................................................................1-3

1.3.3 Adjusting the Pilot Flame ..........................................................................................................1-5

1.3.4 Adjusting Burner Ceramic Target Spacing and Alignment .......................................................1-5

1.3.5 Calibrating the Thermostat ........................................................................................................1-5

1.3.6 Testing the Temperature Probe ..................................................................................................1-7

1.4 Replacing Fryer Components ..............................................................................................................1-7

1.4.1 Replacing a Controller or Computer .........................................................................................1-7

1.4.2 Replacing the Operating Thermostat in Units with Thermostat Control Panels .......................1-8

1.4.3 Replacing the Operating Thermostat in Units with Thermostat Access Doors .........................1-8

1.4.4 Replacing the Temperature Probe .............................................................................................1-9

1.4.5 Replacing the High-Limit Thermostat in Fryers with Thermostat Controls .............................1-9

1.4.6 Replacing the High-Limit Thermostat in Fryers with Other Controls ......................................1-9

1.4.7 Replacing the Heat Mode Indicator Light in Fryers with Thermostat Controls .....................1-10

1.4.8 Replacing the Power or Melt Cycle Switch in Fryers with Thermostat Controls ...................1-10

1.4.9 Replacing Burner Ceramic Targets .........................................................................................1-11

1.4.10 Replacing the Gas Valve ........................................................................................................1-11

1.4.11 Replacing the Pilot Assembly or Thermopile ........................................................................1-12

1.4.12 Replacing the Frypot .............................................................................................................1-12

1.4.13 Replacing the Pump/Motor ...................................................................................................1-14

1.5 Troubleshooting and Problem Isolation .............................................................................................1-15

1.5.1 T ypical Problems .....................................................................................................................1-15

Pilot Failure .............................................................................................................................1-15

Ignition Failure ........................................................................................................................1-15

Improper Burner Function .......................................................................................................1-16

Improper T emperature Control ................................................................................................1-18

Gas Valve Malfunction ............................................................................................................1-18

Computer Malfunction ............................................................................................................1-18

Filtration Malfunction .............................................................................................................1-20

Leakage ...................................................................................................................................1-22

Basket Lift Malfunction ..........................................................................................................1-22

1.5.2 Interpretation of Analog Controller Lights .............................................................................1-24

1.6 Probe Resistance Chart ......................................................................................................................1-24

1.7 Troubleshooting Guides ....................................................................................................................1-25

1.7.1 Troubleshooting the 24 VAC Circuit: Analog Controller........................................................1-25

Troubleshooting the 24 VAC Circuit: Electronic Ignition (Computer Controller) .................1-25

Troubleshooting the 24 VAC Circuit: Standing Pilot (Computer Controller) ........................1-26

1.7.2 Troubleshooting the Gas Valve ...............................................................................................1-26

1.7.3 Troubleshooting the Thermostat .............................................................................................1-26

1.7.4 Troubleshooting the Temperature Probe .................................................................................1-27

1.8 Wiring Diagrams ...............................................................................................................................1-28

1.8.1 Standing Pilot ..........................................................................................................................1-28

1.8.2 Electronic Ignition ...................................................................................................................1-29

1.8.3 Non-Computer Controlled ......................................................................................................1-30

1.8.4 Electronic Ignition ...................................................................................................................1-31

1.8.5 Filter Box ................................................................................................................................1-32

1.8.6 Modular Basket Lift 100/120V ...............................................................................................1-33

1.8.7 Modular Basket Lift 208/250V ...............................................................................................1-34

PERFORMANCE PRO SERIES GAS FRYERS MODELS 35 & 45

Table of Contents

CHAPTER 2: Parts List

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

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

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

2.3.1 FPP/FMP Model Cabinetry .......................................................................................................2-4

2.3.2 PMJ (Non-ﬁ lter) Model Cabinetry ............................................................................................2-6

2.4 Casters, Legs, and Associated Hardware .............................................................................................2-8

2.5 Component Boxes ................................................................................................................................2-9

2.6 Control Panel Assemblies, Flue Caps, and Related Items .................................................................2-11

2.7 Controller Assemblies ........................................................................................................................2-13

2.8 Door Assembly...................................................................................................................................2-15

2.9 Drain System Components ................................................................................................................2-16

2.9.1 Drain Tube System ..................................................................................................................2-16

2.9.2 Drain Valves; FPP/FMP Models ..............................................................................................2-17

2.9.3 Drain Valves; PMJ Models ......................................................................................................2-19

2.10 Filter Boxes ......................................................................................................................................2-20

2.11 Filter Pan Assembly .........................................................................................................................2-22

2.12 Frypots .............................................................................................................................................2-23

2.13 Frypot Cabinetry ..............................................................................................................................2-24

2.13.1 PMJ45 Frypot Cabinetry ........................................................................................................2-24

2.13.2 PMJ35 Frypot Cabinetry ........................................................................................................2-25

2.14 Gas Valves and Burners ...................................................................................................................2-26

2.14.1 PMJ45 Gas Valves and Burners .............................................................................................2-26

2.14.2 PMJ35 Gas Valves and Burners .............................................................................................2-28

2.14.3 Ignitors ...................................................................................................................................2-30

2.15 Oil Return Components ...................................................................................................................2-31

2.16 Oil Return Assembly ........................................................................................................................2-33

2.17 Thermostats and Timers ...................................................................................................................2-34

2.18 Wiring Harnesses, Pin Terminals, and Power Cords .......................................................................2-35

2.19 Garland Range (S35) Parts ...............................................................................................................2-36

2.20 Power Shower ..................................................................................................................................2-36

PERFORMANCE PRO SERIES GAS FRYERS MODELS 35 & 45

CHAPTER 1: SERVICE PROCEDURES

1.1 General

Performance Pro Series gas fryers (formerly Master Jet 35- and 45-series fryers) contain a welded stainless steel frypot directly heated by gas ﬂ ames diffused evenly over its lower surface by ceramic targets. The ﬂ ames originate from oriﬁ ces in a U-shaped burner manifold positioned beneath the frypot. They are equipped with either a millivolt gas valve or electromechanical gas valve that regulates gas ﬂ ow to the manifold. For operating information, refer to the Performance Pro Series Gas Fryers Models 35 & 45 Installation and Operation manual (P/N 819-6042). (Furthermore, referred to as the Installation and Operation manual.)

1.1.1 Pilot Ignition

The pilot system is the pilot oriﬁ ce, pilot hood, and thermopile. The pilot serves two purposes: lighting the burners and heating the thermopile. In operation, the thermopile is in contact with the pilot ﬂ ame and generates millivolts. The millivolt output passes through a normally closed high-limit switch and energizes the gas valve pilot coil, which opens the pilot valve. If the pilot ﬂ ame is extinguished, the gas valve pilot coil loses voltage and the pilot valve closes.

In units equipped with 24-volt electromechanical gas valves, a separate 24-volt circuit activated by the fryer power switch provides voltage through the thermostat or controller to the gas valve main coil, which opens the main valve. The main gas valve will not open if the pilot valve is not open. Light the pilot ﬂ ame manually using a match or the optional built-in piezo ignitor after installing the fryer.

1.1.2 Electronic Ignition

In units conﬁ gured for electronic ignition, a black ignition module connected to an ignitor assembly replaces the pilot system. The ignition module performs three important functions: supply voltage to the gas valve, provide an ignition spark, and proof the pilot ﬂ ame. The module contains a 4.5-second time delay circuit and a coil that activates the gas valve. The ignitor assembly consists of a spark plug, a pilot, and a ﬂ ame sensor element.

At start-up the power switch is placed in the ON position, supplying 12 VDC to the heat control circuitry in the controller or computer and to one side of the heat relay coil on the interface board. If resistance in the temperature probe indicates the temperature in the frypot is below 180°F (82°C), the current ﬂ ows through a melt cycle circuit where a timer switch alternately closes for 3 seconds and opens for 24 seconds. If the temperature is 180°F (82°C) or above, the current ﬂ ows through a heat circuit, bypassing the timer switch. In either case, current is supplied to the other leg of the heat relay coil, which closes an electronic switch in the 24 VAC circuit to provide current to the ignition module.

Circuitry in the ignition module sends 24 VAC current to the gas valve via a normally closed high-limit switch and a drain safety switch. Simultaneously, the module causes the ignitor to spark for 4 seconds to light the pilot ﬂ ame. A ﬂ ame sensor veriﬁ es that the pilot is lit by measuring the ﬂ ow of microamps through the ﬂ ame (can vary, averages 1.9 microamps). If the pilot does not light or is extinguished, current to the ignition module is stopped, preventing the main valve from opening, and the ignition module locks out until the power switch is turned OFF, then back ON.

1-1

1.1.3 Controller Options

Performance Pro gas fryers may be equipped with thermostat controls, analog controllers, digital controllers, basket lift timers, or Computer Magic computers. In fryers equipped with thermostat control panels, the fryer and melt cycle are turned on and off using rocker switches and the temperature is set by a knob connected directly to the frypot-mounted thermostat. These units have no interface board. When the melt cycle switch is placed in the ON position, the fryer stays in the melt cycle mode until the switch is manually placed in the OFF position, even if the oil is at setpoint temperature. In units equipped with thermostat access doors, the temperature control knob is located behind the hinged front panel. Service procedures for this type of thermostat are slightly different from units with other thermostat controls.

Fryers equipped with other types of controllers have an interface board located in the component shield behind the control panel.

1.1.4 Thermostats and Temperature Probes

Performance Pro gas fryers may have different kinds of thermostats depending on their conﬁ guration. Fryers equipped with thermostat controls have an adjustable controlling thermostat. Adjust the temperature at which the thermostat opens and closes by turning the attached knob. The Fenwal controlling thermostat used in these fryers is sensitive to 1° changes in temperature.

Fryers equipped with other types of controls have a temperature probe. In these units, the probe resistance varies directly with the temperature. As the temperature rises, so does the amount of resistance at a rate of approximately 2 ohms for every 1° (F or C) of temperature (see Probe Resistance Chart, Section 1.6). Circuitry in the controller monitors the probe resistance and controls burner ﬁ ring when the resistance exceeds or falls below programmed temperatures (i.e., setpoint). To program temperatures into the fryer, use the keypad on the face of the controller. When testing temperature probes, unplug the 15-pin wiring harness from the controller; otherwise, the reading may be incorrect due to extra resistance.

All open burner fryers are equipped with a high-limit thermostat. If the fryer fails to properly control oil temperature, the high-limit thermostat prevents the fryer from overheating to ﬂ ash point. The high-limit thermostat acts as a normally closed power switch that opens when exposed to temperatures between 425°F to 450°F (218°C to 232°C). It will automatically reset when the oil temperature drops below 350°F (177°C).

1.2 Moving the Fryer for Servicing

If it is necessary to move the fryer before servicing, complete the following actions:

1. Drain the frypot.

2. Turn off the gas supply to the unit. Unplug any power cords. Disconnect the unit from the gas supply.

3. Remove attached restraining devices, including chain restraints and anchor straps.

4. Relocate the fryer to an appropriate area for servicing.

1-2

After servicing is complete:

5. Return the fryer to its original location, reconnect the unit to the gas supply , and open the gas supply valve. Be sure to reattach all restraining devices and plug in all electrical cords.

6. Reﬁ ll the fryer with oil.

1.3 Diagnostic Procedures

1.3.1 Cleaning the Gas Valve Vent Tube

1. Carefully unscrew the vent tube from the gas valve.

NOTE: Straighten the vent tube for easy removal.

2. Pass a piece of binding wire (.052-inch diameter) or equivalent through the tube to remove obstructions.

3. Remove the wire and blow through the tube to ensure that it is clear.

4. Reinstall the tube and bend it so that the opening is pointing down.

1.3.2 Checking the Burner Manifold Gas Pressure

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

2. Remove the pressure tap plug from the end of the manifold.

The frypot must be ﬁ lled with oil or water during this

WARNING

procedure.

3. Connect a manometer or pressure gauge to the port.

Remove this plug and connect a manometer or pressure gauge to the port.

4. Place the gas valve in the PILOT position and light. When the burner lights and continues to burn, note the gas pressure reading and compare it to the accompanying tables.

To adjust burner gas pressure:

5. On non-CE valves, remove the cap from the regulator adjustment screw.

6. On all units, increase the setting on the thermostat until the burner comes on.

7. Monitor the gas pressure reading on the manometer or pressure gauge.

1-3

35-Series Non-CE Standard

Burner Manifold Gas Pressures

Gas Pressure

Natural

Propane

4.0” W.C.

0.87 kPa

9.0” W.C.

2.24 kPa

35-Series CE Standard

Burner Manifold Gas Pressures

Gas Pressure

Natural Gas Lacq (G20) under 20 mbar

Natural Gas Gronigue* (G25) under 25 mbar

Natural Gas Gronigue* (G20) under 20 mbar

Propane (G31) under 37 or 50 mbar

* Belgian G25 and G20 = 9.0 mbar

9 mbar

11 mbar

22.5 mbar

45-Series Non-CE Standard

Burner Manifold Gas Pressures

Gas Pressure

Natural

Propane

45-Series CE Standard

Burner Manifold Gas Pressures

Gas Pressure

Natural Gas Lacq (G20) under 20 mbar

Natural Gas Gronigue* (G25) under 25 mbar

Natural Gas Gronigue (G20) under 20 mbar

Propane (G31) under 37 or 50 mbar

* Belgian G25 = 7.0 mbar

3.5” W.C.

0.73 kPa

8.25” W.C.

2.05 kPa

7.5 mbar

10 mbar

20.6 mbar

8. Use a ﬂ at-head screwdriver to adjust the gas valve regulator adjustment screw to obtain the prescribed pressure written on the rating plate or one of the charts above. (Use the diagram on below to locate this screw.) Turn the screw clockwise to increase gas pressure and counterclockwise to decrease gas pressure.

9. On non-CE units, reinstall the gas valve regulator cap screw when the correct manifold pressure is obtained.

10. Place the gas valve in the OFF position. Remove the ﬁ tting from the pressure tap hole and reinstall the pressure tap plug.

11. Place the gas valve in the PILOT position. Re-light and check for any gas leaks.

12. Place the gas valve in the OFF position.

To access the pilot adjustment screw on non-CE valves, this cap must be removed.

Pilot Adjustment Screw

Gas Valve Regulator

Adjustment Screw

Honeywell Valve

(Non-CE Units)

Locating the gas valve regulator adjustment screw and pilot adjustment screw.

Honeywell Valve

(CE Units)

1-4

1.3.3 Adjusting the Pilot Flame

1. On non-CE valves, remove the cap covering the pilot adjustment screw. On all valves, use a ﬂ at- tipped screwdriver to turn the pilot adjustment screw counterclockwise to increase the length of the ﬂ ame or clockwise to decrease the length of the ﬂ ame. (Use the diagram on the previous page to locate this screw.) Adjust the ﬂ ame to a length of 1- to 1½- inches (25 to 38 mm).

2. On non-CE valves, reinstall the pilot adjustment screw cap.

1.3.4 Adjusting Burner Ceramic Target Spacing and Alignment

Proper spacing of the top edge of the ceramic targets is ¾-inch (13 mm) from the frypot side. To adjust target spacing, bend the brackets away or toward the frypot, as needed. A length of board ¾-inch thick is useful as a gauge to verify spacing and alignment.

¾-inch

There should be approximately ¾-inch spacing between the top edge of the targets and the side of the frypot.

1.3.5 Calibrating the Thermostat

Fryers with thermostat access doors:

1. Fill the frypot to the lower OIL-LEVEL line with cooking oil. If using solid shortening, pack it tightly into the frypot before starting the calibration procedure.

2. Light the pilot. (See Chapter 3 of the Installation and Operation manual for detailed lighting instructions.)

3. Insert a thermometer or pyrometer into the frypot, about 1-inch from the thermostat.

4. Open the thermostat access door and set the thermostat on the fryer to 325°F (162°C).

5. When oil reaches 325°F (162°C), allow the burners to cycle on and off three times.

6. Take a temperature reading when the burners go off for the third time.

7. Loosen the setscrews in the thermostat knob and turn the knob to the temperature established by the thermometer/pyrometer reading.

1-5

8. Allow the burners to cycle on and off three more times and recheck the thermometer/pyrometer reading against the thermostat setting. Temperature readings should be within 5°F (2.8°C) of setpoint.

Fryers with thermostat control panels:

NOTE: Remove the thermostat knob from its shaft to allow the control panel to hinge downward. Follow the instructions in Section 1.4.2 to remove the knob and control panel.

1. Fill the frypot to the lower OIL-LEVEL line with cooking oil. If using solid shortening, pre-melt it before starting the calibration procedure.

2. Ensure the fryer power switch is in the OFF position, and light the pilot. (Refer to Chapter 3 of the Installation and Operation manual for detailed lighting instructions.)

3. Insert a thermometer or pyrometer into the frypot so that it touches the thermostat guard.

4. Loosen the setscrew and stop screw securing the thermostat shaft extension to the ﬂ exible shaft. Remove the extension to expose the slot in the end of the ﬂ exible shaft.

5. Place the fryer power switch in the ON position.

NOTE: If the burner does not light at this time, it does not

mean the thermostat is defective.

Use a small ﬂ at-head screwdriver to slowly turn the ﬂ exible shaft counterclockwise until the burner

lights.

6. When the oil temperature reaches 325°F (162°C), slowly turn the ﬂ exible shaft clockwise until the burner turns off. Then, allow the fryer to sit for a few minutes.

7. Repeat Steps 5 and 6 at least three times to ensure that the setting is accurate. The thermostat control is considered properly calibrated if the burner lights when the cooking oil cools to 325°F (162°C).

Do not take the reading when the burner shuts off after raising the temperature.

The thermostat ﬂ exible shaft must not be rotated while installing the thermostat shaft extension!

Do not rotate the ﬂ exible shaft more than two turns in either direction. Doing so will cause damage to the thermostat.

CAUTION

8. Once the thermostat is calibrated, allow the burner to cycle on and off at least three times to ensure that it lights at the correct temperature.

9. After the calibration is complete, place the fryer power switch in the OFF position and disconnect the fryer from the electrical supply.

10. Carefully replace the thermostat shaft extension so that the stop screw points straight up. Without rotating the ﬂ exible shaft, tighten the stop screw, locking nut, and setscrew.

11. Close the fryer control panel and replace the screws and bezel.

12. Reinstall the thermostat knob. Align its pointer with the 325°F (162°C) index mark on the temperature dial.

13. Reconnect the fryer to the electrical supply.

1-6

1.3.6 Testing the Temperature Probe

1. While it is still in the frypot, inspect the probe body for damage. Inspect the leads for fraying,

burning, breaks, or kinks. If the probe is bent, dented, or cracked, or if the leads are damaged, replace the probe.

2. Determine the temperature of the cooking oil using a thermometer or pyrometer placed at the tip of the probe.

3. Disconnect the 15-pin wiring harness from the interface board. Measure the probe resistance using J2 pins 13 and 14.

4. Resistance should approximately equal the given probe resistance for the corresponding temperature on the chart in Section 1.6, Page 1-23. If not, the probe has failed and must be replaced. Probes cannot be calibrated.

NOTE: A defective probe will cause inaccurate temperature measurements. If the temperature,

as measured by the probe, varies by more than 5°F

(2.8°C!) from the thermometer or pyrometer

reading, the probe should be replaced. Temperature probes cannot be calibrated.

1.4 Replacing Fryer Components

1.4.1 Replacing a Controller or Computer

1. Disconnect the fryer from the electrical power supply.

2. Slide the metal bezel up to disengage the lower tabs. Then, slide the bezel down to disengage the upper tabs.

3. Remove the two screws holding the controller to the control panel frame.

4. Hinge the controller down to access the 15-pin wiring harness on the back and unplug it.

5. Lift the controller up and out of the hinged tab slots.

6. Use a 5/16-inch nut driver (P/N 802-0352) to remove the nut and green grounding wire from the back of the controller.

7. If replacing the 15-pin wiring harness, do so now. Plug the new 15-pin wiring harness into the interface board with the metal ring on the controller-end of the connector.

8. Connect the 15-pin wiring harness and the green ground wire to the new controller. When the connector on the harness is completely engaged, the clips on either side will snap into place.

9. Re-hinge the controller by inserting the tabs on the bottom into the slots on the control frame panel.

10. Move it into the closed position against the control panel frame and replace the screws in the top corners.

11. Insert the top tabs on the bezel into the slots on the underside of the top cap. Slide the bezel down to engage the lower tabs in the lower slots.

1-7

1.4.2 Replacing the Operating Thermostat in Units with Thermostat Control Panels

1. Disconnect the fryer from the electrical power supply. Turn off the gas and disconnect the fryer.

2. Drain the frypot.

3. Loosen the setscrew securing the thermostat knob and remove the knob. Remove the screws from the upper left and right corners of the control panel. The control panel hinges at the bottom and will swing open from the top.

4. Disconnect the 9-pin wiring harness and remove the control panel from the fryer by disengaging its tabs from the hinge slots in the mounting frame.

5. Loosen the setscrews securing the ﬂ exible shaft to the thermostat shaft. Slip the ﬂ exible shaft off the thermostat shaft.

6. Remove the ﬂ exible shaft guide by removing the two sheet metal screws securing it to the upper frame.

7. Disconnect the thermostat leads from pin 14 in the 20-pin terminal block and from the gas valve terminal.

CAUTION The thermostat ﬂ exible shaft must not be rotated while installing the thermostat shaft extension!

Do not rotate the ﬂ exible shaft more than two turns in either direction. Doing so will cause damage to the thermostat.

stop screw

locking nut

setscrew

NOTE: If the fryer has a melt cycle, the thermostat leads

connect to the PC board rather than to the terminal block and gas valve. Disconnect the leads from the PC board if this is

the case.

8. Unscrew the thermostat from the frypot and remove it.

9. Apply Loctite™ PST56765 thread sealant or equivalent to the threads of the replacement thermostat.

10. Reverse Steps 1-8 to install the replacement thermostat.

Loosen these setscrews and slip the ﬂ exible shaft off of the thermostat shaft.

1.4.3 Replacing the Operating Thermostat in Units with Thermostat Access Doors

1. Disconnect the fryer from the electrical power supply. Turn off the gas and disconnect the fryer.

2. Drain the frypot.

3. Use an allen wrench to loosen the setscrew at the side of the thermostat knob. Remove the knob.

4. Remove the two setscrews on both sides of the thermostat shaft and remove the dial plate.

5. Disconnect the thermostat wires from the gas valve.

6. Use a slotted socket to unscrew the thermostat from the frypot.

7. Apply Loctite™ PST56765 thread sealant or equivalent to the threads of the replacement thermostat.

8. Reverse Steps 1-7 to install the replacement thermostat.

1-8

1.4.4 Replacing the Temperature Probe

1. Disconnect the fryer from the electrical supply.

Drain the frypot before pro-

2. Drain the frypot.

3. Remove the controller or computer according to the instructions in Section 1.4.1.

4. Unplug the 12-pin wiring harness from the front of the interface board.

5. Use a pin-pusher to remove the temperature probe wires (pins 1 and 2) from the 12-pin wiring harness

6. Unscrew the temperature probe from the frypot and remove.

7. Apply Loctite™ PST56765 thread sealant or equivalent to threads of the replacement probe.

8. Screw the new probe into the frypot.

9. Reverse Steps 1-5 to reassemble.

10. Check the probe according to the instructions in Section 1.3.6.

1.4.5 Replacing the High-Limit Thermostat in Fryers with Thermostat Controls

ceeding.

CAUTION

1. Disconnect the fryer from the electrical supply.

Drain the frypot before pro-

2. Drain the frypot.

3. Remove the thermostat knob and/or control panel as instructed in Section 1.4.2 or 1.4.3.

4. Disconnect the high-limit thermostat leads from the gas valve pilot coil.

5. Unscrew the high-limit thermostat from the fryer and remove.

6. Apply Loctite™ PST56765 thread sealant or equivalent to the threads of the replacement high-limit thermostat.

7. Reverse Steps 1-5 to the install replacement high-limit.

1.4.6 Replacing the High-Limit Thermostat in Fryers with Other Controls

1. Disconnect the fryer from the electrical supply.

2. Drain the frypot.

3. Remove the bezel and controller as instructed in Section 1.4.1, Steps 2 and 3.

ceeding.

Drain the frypot before proceeding.

CAUTION

4. Unplug the 15-pin wiring harness and grounding wire from the controller.

5. Remove the high-limit thermostat wires from the gas valve pilot coil.

1-9

6. Unscrew the high-limit thermostat from the fryer and remove it.

7. Attach the appropriate terminals (instructions furnished in the replacement kit) to the thermostat leads.

8. Apply Loctite™ PST56765 thread sealant or equivalent to the threads of the replacement high-limit thermostat.

9. Reverse Steps 1-6 to install the replacement high-limit.

1.4.7 Replacing the Heat Mode Indicator Light in Fryers with Thermostat Controls

1. Disconnect the fryer from the electrical power supply.

2. Remove the thermostat knob and control panel as instructed in Section 1.4.2 or 1.4.3, as appropriate.

3. Carefully press the light out from the back of the control panel.

4. Disconnect one wire at a time and reconnect it to the replacement light (before disconnecting the next wire). Continue until all wires are transferred.

5. Carefully press the light back into the control panel.

6. Reinstall the thermostat knob and control panel by reversing Step 2.

7. Reconnect the fryer to the electrical power supply.

1.4.8 Replacing the Power or Melt Cycle Switch in Fryers with Thermostat Controls

1. Disconnect the fryer from the electrical power supply.

2. Remove the thermostat knob and control panel as instructed in Section 1.4.2.

3. Using a ﬂ at-head screwdriver, disconnect the chrome bezel from the tabs on the switch and press the switch out from the front.

4. Carefully press the new switch into the chrome bezel, making sure the tabs on the switch engage the slots in the bezel.

5. Disconnect one wire at a time and reconnect it to the replacement switch (before disconnecting the next wire). Continue until all wires are transferred.

6. Reinstall the thermostat knob and control panel by reversing Step 2.

7. Reconnect the fryer to the electrical power supply.

1-10

1.4.9 Replacing Burner Ceramic Targets

1. Disconnect the fryer from the electrical power supply. Turn off the gas and disconnect the fryer.

2. Drain the frypot or remove the handle from the drain valve.

3. Remove the round drain sections as necessary to expose the burners and heat shield.

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

5. Remove the high-limit thermostat wires from the gas valve pilot coil.

6. Disconnect the pipe union collar located on the bottom of the gas valve.

7. Remove the burner heat shield hanger screws at the front of the burner and remove the heat shield.

In units with built-in ﬁ ltration, there may be a second heat shield located under the burner manifold.

Remove the screws holding it in place and remove it.

8. Remove the ﬁ lter pan by sliding it out of the unit and lifting it up and out of the roller track.

9. Remove the burner hanger screws and lower the front of the main burner . Pull it forward to clear the rear burner hanger and lower the burner to the ﬂ oor.

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

WARNING

10. Raise the front of the fryer enough to slide the burner from under the fryer cabinet.

11. To replace only the ceramic targets, straighten the target locking tabs with a pair of needle nose pliers or a screwdriver and slide the target up and off the bracket. Slide the replacement target onto the bracket and bend the locking tabs down.

To replace the entire target assembly, use a ½-inch (13mm) box end wrench to remove the two brass

oriﬁ ces that hold the assembly to the burner manifold. Position the new assembly and replace the oriﬁ ces.

12. Reverse Steps 1-9 to reinstall the burner assembly. Compare spacing and alignment of targets with the parameters in Section 1.3.4.

1.4.10 Replacing the Gas Valve

1. Disconnect the fryer from the electrical power supply. Turn off the gas and disconnect the fryer.

2. Drain the frypot or remove the handle from the drain valve.

Avoid cross-threading and stripping when reinstalling the brass oriﬁ ces.

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

CAUTION

WARNING

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

1-11

4. Remove the high-limit thermostat wire from the gas valve pilot coil.

5. Disconnect the pilot gas line ﬁ tting from the gas valve.

6. Disconnect both pipe union collars from the gas valve and remove the valve.

7. Remove the pipeﬁ ttings from the old gas valve and install them on the replacement valve. Use Loctite™ PST56765 or equivalent pipe thread sealant on the threads.

8. Reverse Steps 1-6 to install the replacement gas valve.

WARNING

1.4.11 Replacing the Pilot Assembly or Thermopile

Drain the frypot or remove the handle from the drain valve

1. Remove the burner assembly in accordance with Steps 1-10

before proceeding further.

in Section 1.4.9.

2. To replace only the thermopile:

a. Bend the clip at the bottom of the pilot assembly and press

the thermopile out of the pilot assembly from the top. b. Disconnect the thermopile ﬁ tting from the gas valve pilot coil. c. Reverse Steps a and b to install the replacement thermopile.

3. To replace the complete pilot assembly:

Bend the clip to release the thermopile.

a. Disconnect the pilot tubing from the bottom of the pilot assembly. b. Remove the screw from the pilot mounting bracket to release the pilot assembly. c. Disconnect the thermopile ﬁ tting from the gas valve pilot coil. d. Reverse Steps a-c to install the replacement assembly.

4. Reinstall the burner assembly by reversing Steps 1-8 of Section 1.4.9.

1.4.12 Replacing the Frypot

1. Drain the frypot.

2. Disconnect the fryer from the electrical power supply. Turn off the gas supply and disconnect the fryer.

3. Remove all accessories (i.e., frypot covers, basket lift arms, etc.) from the fryer.

4. If the fryer is equipped with a thermostat control, remove the thermostat knob and control panel according to Steps 3-8 in Section 1.4.3.

NOTE: If the fryer is conﬁ gured with a melt cycle, the thermostat leads will be connected to the PC board

rather than to the terminal block and gas valve. Disconnect the leads from the PC board if this is the case.

1-12

5. If the fryer is not equipped with a thermostat control, remove the controller according to Steps 2-6 in Section 1.4.1.

6. Disconnect the 12-pin plug from the interface board. Use a pin-pusher to remove the temperature probe wires (pins 1 and 2) and the high-limit thermostat leads (pins 6 and 8) from the plug. Leave all other wires connected.

7. Remove the control panel frame by removing the screws in the upper left and right corners that secure the control panel to the topcap. Remove the screws in the top and bottom holes of each brace of the control panel that secure it to the fryer. Pull the control panel straight out of the fryer frame. It may require a rubber mallet to loosen it.

8. Disconnect the wires from the components in the component shield and mark to facilitate reconnection.

9. Disconnect the wires from the gas valve terminal block and mark each to facilitate reconnection.

10. Remove the cover from the drain safety switch, disconnect the wires from the switch, and pull them out of the switch box.

11. Pull up and forward on the component shield to clear the rear mounting stud on the front of the frypot and remove it from the fryer by rotating its right side up and to the left.

12. Disconnect the pipe union on the bottom of the gas valve.

13. On units with ﬁ ltration, disconnect the section of drain connected to the drain valve of the frypot to be removed.

14. Take off the topcap by removing the pairs of screws from each tab in the upper corners. Pull up to slide it off the fryer. It may require a rubber mallet to loosen it.

15. Remove the frypot hold-down bracket, which attaches the front of the frypot to the frame of the fryer. It is held in place by three screws: two securing it to the frame and one securing it to the frypot.

16. Remove the ﬂ ue cap:

a. Remove all of the screws attaching the back panels to the

fryer and remove the panels.

b. Remove the screws in the bottom left and right corners of

the ﬂ ue cap.

c. Slide the ﬂ ue cap up to remove it.

17. Remove the oil return line from the front of the frypot to be removed.

Clean all threads and apply Loctite™ PST56765 thread sealant or equivalent when installing the drain valve, high-limit, and thermostat or temperature probe on the replacement frypot.

CAUTION

18. Lift the complete frypot assembly (frypot, burner, gas valve, and ﬂ ue) from the fryer cabinet.

19. Transfer the burner heat shield and burner to the replacement frypot.

20. Remove the drain valve, thermostat or temperature probe, and high-limit thermostat and install them on the replacement frypot.

1-13

21. In units with multiple frypots, add a bead of silicon along the joint between the frypots to ensure a seal. Then, insert the top connecting strip.

22. Reverse Steps 1-25 to reassemble the fryer.

1.4.13 Replacing a Pump/Motor

1. Disconnect the unit from the electrical power supply.

2. Remove the ﬁ lter pan from the unit and drain the frypots into a Shortening Disposal Unit (SDU) or

other appropriate metal container.

DO NOT attempt to drain more than one full frypot or two split frypots into the SDU at one time.

3. Position a container beneath the oil return ﬁ tting at the front of the cabinet. Disconnect the ﬂ exible

oil line from the ﬁ tting, allowing any residual oil to drain into the container.

4. At the rear of the fryer, unplug the left connector (as viewed from the rear of the fryer) from the

transformer box. Using a pin pusher, push the pump solenoid valve wires from Pins 7 and 9.

5. Remove the four nuts and bolts attaching the motor mount to the rear motor mount support.

6. At the front of the fryer, remove the cover plate from the front of the motor and disconnect the motor

wires.

7. Place a 1-foot (30.5-cm) length of wood (or similar support) beneath the motor mount near the front

of the unit and remove the two remaining nuts and bolts attaching the motor mount to the front cabinet cross-brace.

8. Carefully remove the support and lower the motor mount to the ﬂ oor, allowing the rear of the mount

to slide forward and off the rear motor mount support.

9. Disconnect the Power Shower ﬂ exline (if applicable) or the oil return ﬂ exline from the pump. The

motor and pump assembly can now be pulled from beneath the fryer and the failed component can be removed and replaced.

10. Position the new/repaired motor and pump assembly beneath the fryer and reconnect the Power

Shower ﬂ exline (if applicable) or the oil return ﬂ exline to the pump. Lift the rear of the motor mount up and onto the rear motor mount support.

11. Lift the front of the motor mount up and support it with a 1-foot (30.5-cm) piece of wood or a similar

support. Install but do not tighten the two nuts and bolts that attach the motor mount to the front cabinet cross-brace.

DANGER

12. Install and tighten the four nuts and bolts that secure the motor mount to the rear motor mount

support. Reconnect the solenoid valve wires to Pins 7 and 9 of the 9-pin connector (polarity does not matter) and reconnect the plug.

13. At the front of the fryer, tighten the two nuts and bolts at the front of the motor mount. Reconnect

the motor power wires and reinstall the wiring cover plate.

14. Reconnect the oil return ﬂ exline and reinstall the ﬁ lter pan.

15. Reconnect the unit to the electrical power supply, ﬁ ll the frypots with oil, and check for proper

operation.

1.5 Troubleshooting and Problem Isolation

Because it is not feasible to include every issue that might occur, this section is intended to provide technicians with a general knowledge of the broad problem categories associated with this equipment and the probable causes of each. With this knowledge, the technician should be able to isolate and

1-14

correct any problem encountered.

1.5.1 Typical Problems

You are likely to encounter problems in these broad categories:

1. Pilot Failure

2. Ignition Failure

3. Improper Burner Function

4. Improper Temperature Control

5. Gas Valve Malfunction

Read the following sections to learn more about each category. A series of troubleshooting guides is also included at the end of the chapter to assist in identifying some of the more common problems. In addition, Section 1.5.2 will guide technicians through interpretation of digital controller lights, helpful in diagnosing problems.

Pilot Failure

There are two types of pilot failure: no pilot ﬂ ame and unreliable pilot ﬂ ame.

No pilot ﬂ ame:

• Insufﬁ cient gas supply

• Clogged pilot oriﬁ ce

• Air in gas lines (usually in new installations).

6. Computer Malfunction

7. Filtration Malfunction

8. Leakage

9. Basket Lift Malfunction

Unreliable pilot ﬂ ame:

• Open or grounded high limit

• Loose or corroded wire connections

• Low or no voltage out of thermopile

• Bad gas valve.

Ignition Failure

Ignition failure occurs when the gas valve no longer receives power, the gas supply stops, or the pilot ﬂ ame goes out. Solid-state controllers indicate ignition failure by illuminating the heat light and trouble light simultaneously . Computers and digital timers will read HELP to indicate ignition failure. There are three primary areas of focus in diagnosing and correcting ignition failure:

1. The gas and electrical power supplies

2. The electronic circuits

3. The gas valve.

The Gas and Electrical Power Supplies

The main indicators that the gas or electrical power supply is the cause of ignition failure are as follows: an entire battery of fryers fails to light, and/or there are no indicator lights illuminated on the fryer experiencing ignition failure. Verify that the quick disconnect hose is properly connected, the fryer is plugged in, the main gas supply valve is open, and the circuit breaker for the fryer electrical supply is not tripped.

1-15

The Electronic Circuits

If the fryer is receiving gas and electrical power, the next most likely cause of ignition failure is a problem in the 24 VAC circuit of the pilot system. If the fryer is equipped with a drain valve for ﬁ ltration purposes, check the drain valve to verify that it is fully closed. A microswitch attached to the valve must be closed for power to reach the gas valve. Often, although the valve handle appears to be in the closed position, the microswitch is still open. If the valve is fully closed, or the fryer is not equipped with a ﬁ ltration system, refer to Troubleshooting the 24 VAC Circuit in Section 1.7.1 of this manual.

The Gas Valve

If the problem is not in the 24 VAC circuit of the pilot system, it is most likely in the gas valve. However, before replacing the gas valve, refer to Troubleshooting the Gas Valve in Section 1.7.2 of this manual.

Improper Burner Function

In these types of instances, the burner ignites but exhibits abnormal characteristics, such as popping, incomplete lighting of the burner, ﬂ uctuating ﬂ ame intensity, and ﬂ ames “rolling” out of the fryer.

Popping indicates delayed ignition. In most cases, the main gas valve is opening, but the burner is not immediately lighting. When ignition does take place, excess gas bursts into ﬂ ame suddenly, rather than smoothly igniting.

The primary causes of popping are:

1. Incorrect or ﬂ uctuating gas pressure

2. Misdirected or weak pilot ﬂ ame

3. Clogged burner oriﬁ ces

4. Inadequate make-up air

5. Missing or misaligned burner deﬂ ector targets

6. Clogged vent tube (causing incorrect gas pressure).

Incorrect or Fluctuating Gas Pressure

If popping occurs only during peak hours, the problem may be incorrect or ﬂ uctuating gas pressure. Verify that the incoming gas pressure (to the gas valve) is in accordance with the appropriate CE or nonCE standard found in the table on Page 1-4 and the pressure remains constant throughout all hours of usage. Refer to Checking the Burner Manifold Pressure in Section 1.3.2 for instructions on checking the pressure of gas supplied to the burner.

Misdirected or Weak Pilot Flame

If popping is consistent during all hours of operation, check position of the pilot above the burner oriﬁ ce and verify that the pilot pressure is correct. A 1- to 1 ½-inch (25 to 38 mm) ﬂ ame indicates correct pilot pressure. Refer to Section 1.3.3 for information on pilot ﬂ ame adjustment.

Clogged Burner Oriﬁ ces

1-16

Clogged burner oriﬁ ces, especially those near the pilot, are also likely causes of delayed ignition. Lack of ﬂ ame, ﬂ ames that are orange in color, and ﬂ ames that shoot out at an angle from the rest are indications of clogged burner oriﬁ ces. If only one side of the burner is lighting, the rear deﬂ ector target may be misaligned or missing completely. Improper burner pressure may also cause this. If there are gaps in

burner ﬁ ring, check for clogged burner oriﬁ ces.

Inadequate Make-up Air

Another cause of popping is an insufﬁ cient air supply or drafts that are blowing the pilot ﬂ ame away from the burner. Check for negative pressure conditions in the kitchen area. If air is ﬂ owing into the kitchen area, this indicates that more air is entering the kitchen than is leaving it. In a negative pressure environment, the burners may not be receiving an adequate amount of air to maintain a strong pilot ﬂ ame.

Other Causes of Popping

Other causes of popping are more ambiguous and may have two or more possible causes to consider.

If the fryer’s gas and air supplies are okay, it is likely that the cause of the popping is one of the electrical components. Examine the controller for signs of melting, distortion, and possibly discoloration due to excessive heat buildup in the fryer (usually indicating improper ﬂ ue performance). Automatically suspect a discolored or distorted controller and replace it. However, it is important to diagnose and correct the condition causing excessive heat in the fryer or the problem is likely to recur.

Fluctuating ﬂ ame intensity is normally caused by improper or ﬂ uctuating gas pressure or the result of variations in the kitchen atmosphere. Verify incoming gas pressure in the same way as for popping, discussed in the preceding paragraphs. Air condition and ventilation units (such as hoods) starting and stopping throughout the day usually cause variations in the kitchen atmosphere. As they start and stop, the pressure in the kitchen may change from positive or neutral to negative, or vice versa. They may also cause changes in airﬂ ow patterns that may affect ﬂ ame intensity.

Flames “rolling” out of the fryer are usually an indication of negative pressure in the kitchen. The negative air pressure is sucking air out of the fryer enclosure and the ﬂ ames are following the air. If negative pressure is not the cause, check for high burner manifold gas pressure in accordance with the procedures in Section 1.3.2. An obstructed ﬂ ue, which prevents the fryer from properly exhausting, may also be the cause.

An unusually noisy burner, especially when ﬂ ames are visible above the ﬂ ue opening, may indicate that the burner gas pressure is too high or that the gas valve vent tube is blocked. If the gas pressure is correct and the vent tube is unobstructed, the gas valve regulator is probably defective.

Occasionally , a burner may appear to be operating correctly , but it shows a slow recovery rate (discussed on Page 1-18). The primary causes of this are low burner manifold pressure and misaligned or missing deﬂ ector targets. In some cases, the cause is a gas valve regulator that is out of adjustment. Refer to Section 1.3.2 for instructions on checking the burner manifold pressure and Section 1.3.4 for adjusting deﬂ ector target positioning.

1-17

Improper Temperature Control

T emperature control—including that for the melt cycle—is a function of several interrelated components, each of which must operate correctly. The principal component is the thermostat (in units equipped with thermostat controls) or the temperature probe (in fryers equipped with other types of controllers). Depending upon the speciﬁ c conﬁ guration of the fryer, it may also include an interface board and controller. Problems with improper temperature control can be categorized into those issues concerning melt cycle malfunctions and those concerning a failure to control at setpoint.

Melt Cycle

In fryers equipped with thermostat controls, the melt cycle is controlled with a solid state melt cycle board and a melt cycle switch on the control panel. In all cases, replace the defective component.

In fryers equipped with other types of controllers, the problem may originate in the controller, the temperature probe, or a malfunctioning heat relay on the interface board. For problem isolation techniques, refer to the troubleshooting guides, T roubleshooting the Thermostat and Troubleshooting the Temperature Probe, in Section 1.7, Troubleshooting.

Sediment Particle

Failure to Control at Setpoint

Oil Flow

In fryers equipped with thermostat controls, the problem will be in the thermostat. Refer to Section 1.3.5 for instructions on calibrating the thermostat. Possible causes are that

• the thermostat is out of calibration,

Sediment

Particle

Up for reverse

• the knob or ﬂ exible shaft is loose on the thermostat shaft,

• a thermostat wire is disconnected or broken, or

Down for forward

• the thermostat is defective.

Refer to Section 1.3.5 for instructions on calibrating the thermostat. In fryers equipped with other types of controls, the

Removing debris or shortening from a seized pump.

problem may originate in the temperature probe or probe circuit, the interface board, or the controller. Refer to Troubleshooting the Temperature Probe, Section 1.7.4., for problem isolation techniques.

Gas Valve Malfunction

Occasionally, a gas valve may malfunction. Use Section 1.7.2, Troubleshooting the Gas Valve, to determine if the valve has failed.

Computer Malfunction

Before diagnosing problems related to a computer controller, it is important to understand the use and signiﬁ cance of sensitivity and recovery.

Sensitivity and Recovery

Sensitivity—or “stretch time”—is a programmable feature, patented by Frymaster, which increases or decreases the cook time countdown based on variation in the oil temperature from the setpoint. The

1-18

sensitivity for each product button has ten settings, 0-9. Setting sensitivity to “0” will disable the feature completely , while a setting of “9” will provide the highest sensitivity or most change. The correct sensitivity for any product is based on the type of product, its density, the setpoint temperature, and the customer’s own requirements. A generic sensitivity chart is located on Page 1-5 of the Frymaster Fryer Controllers manual (P/N 819-5916).

Recovery—or “rate of rise”— is a method of measuring a fryer’s performance. It is the time required for the fryer to increase the oil temperature from 275°F to 325°F (135°C to 163°C). This range is the standard since ambient kitchen temperatures can affect the test if lower ranges are used. The Computer Magic computer controller performs the recovery test each day as the fryer heats-up. An operator can view the results of the test any time the fryer is above 325°F (163°C) by pressing the code 1652. The test results display in the computer’s LED panel in minutes and seconds. The acceptable recovery time is 2:30 or less. Extended recovery is a sign that the fryer is not being regularly maintained or it is in need of servicing. The recovery time lengthens as fryer health declines. This is a useful tool for gauging the condition of the fryer and should be checked regularly.

Common Computer Complaints

Most problems with Computer Magic controllers stem from programming issues. There are four common complaints.

button and entering the

1. Fryer constantly displays HI. Cause: Incorrect, low, or missing setpoint. Fix: Press

setpoint.

2. Fryer constantly displays temperature. Cause: The computer has been programmed to constantly display the temperature. Fix: Press 165L.

3. Fryer displays temperature in Celsius. Cause: The computer has been programmed to display in Celsius rather than Fahrenheit. Fix: Press

4. Computer times down too slowly or too quickly. Cause: The computer is compensating for oil temperature via the sensitivity setting.

1650, enter the correct setpoint using the keypad, then press to lock-in the new

1658.

Fix: Reprogram the sensitivity setting for each product by following the programming instructions in

the Installation and Operation manual or the Frymaster Fryers Controllers manual (P/N 819-5916).

1-19

Filtration Malfunction

The majority of ﬁ ltration malfunctions arise from operator error. One of the most common errors is placing the ﬁ lter paper on the bottom of the ﬁ lter pan rather than over the ﬁ lter screen.

Inspect the ﬁ lter paper to ensure that it is correctly sized and placed. Incorrectly sized or installed ﬁ lter paper will allow particles and sediment to pass through the ﬁ lter pan and into the pump. When sediment enters the pump, the gears can bind and cause the motor to overheat. If the motor overheats, the thermal overload will trip to protect the motor from further damage. Reset the motor by pressing the red reset button the end of the motor nearest the operator. Sediment cannot enter the pump when the correct

ﬁ lter paper is used properly.

While you are checking the ﬁ lter paper, verify that the O-rings on the ﬁ lter pan and connectors are present and in good condition. Missing or worn O-rings will allow the pump to suck air and decrease its efﬁ ciency.

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

1. Disconnect power to the ﬁ lter system.

2. Remove the input plumbing from the pump.

3. Use a screwdriver to manually turn the gears.

• Turn the pump gears backward to release a hard particle and remove it.

• Turn the pump gears forward to push softer objects and solid shortening through the pump and allow the gears to move freely.

Incorrectly sized or installed paper will also allow food particles and sediment to pass through and clog the suction tube on the bottom of the ﬁ lter carriage. Particles large enough to block the suction tube may indicate that the crumb tray is not being used during ﬁ ltering.

Pan blockage can also occur if shortening remains in the pan and solidiﬁ es. The heater strip on the suction tube prevents solidiﬁ cation of residual shortening left in the tube. It will not melt or prevent solidiﬁ cation of shortening in the pan. Remove blockages 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.

The Power Shower may need service for clogged openings, shortening solidiﬁ ed in the tubes, missing clean-out plugs, and missing or worn O-rings. T o correct these problems, clean the unit and replace missing or worn plugs and O-rings.

1-20

Manual (Push-Button)

Modular Basket Lift Simplified Schematic

2-Pole

When the timer button is pushed, the lower circuit is activated. The basket lift lowers, closing the normally open upper microswitch. The motor loses power when the basket lift rod moves down and opens the lower, normally closed microswitch. When the timer times-out, the upper circuit is activated. The basket lift rises, closing the lower microswitch. When the rod clears the upper microswitch, it opens and power is again cut to the motor. Pushing the timer button again restarts the cycle.

Mech Timer

1 or 5

4 or 6

N.O. Upper Limit Microswitch

N.C. Lower Limit Microswitch

Computer/Controller

Modular Basket Lift Simplified Schematic

N.O. Upper Limit Microswitch

1 or 4

To computer/controller via interface board

When the product button is pushed on the computer/controller, current flows through a coil in the basket lift relay. The lower circuit is activated and the basket lift lowers, closing the upper, normally open microswitch. The basket lift rod moves down, opening the lower, normally closed microswitch and removing power from the motor. When the computer/controller times-out, the relay coil loses current and the upper circuit is activated. The basket lift rises, closing the lower microswitch. When the rod opens the upper microswitch, power to the motor is lost again. Pushing the product button again restarts the cycle.

Basket Lift Relay

N.C. Lower Limit Microswitch

1-21

Leakage

When a frypot appears to be leaking, suspect the areas where high-limit thermostats, temperature probes, and drain ﬁ ttings attach to the frypot. When installed or replaced, seal each of these components with Loctite PST56765 sealant or equivalent to prevent leakage.

If oil coats the sides or ends of the frypot, the most likely cause is spillage over the top of the frypot. There may also be oil pooled on the ﬂ oor below the fryer. This is not necessarily a sign that the frypot is leaking.

It is important to check the joints between round drain sections and all of the ﬁ ttings. If removing a section of drain tube connected to the drain valve for any reason, make sure that the O-rings are in good condition and properly ﬁ tted within the drain during reinstallation. Ensure that the clamps are tight and that the nut holding them onto the stud of the tube is not stripped or loose. Also, check that the drain tube runs downward from the drain along its whole length and has no low points where oil may accumulate.

In very rare cases, a leak may develop along one of the welded edges of the frypot. When this type of leak is suspected, thoroughly inspect the frypot. If it is deﬁ nitely leaking, replace the frypot.

Basket Lift Malfunction

Performance Pro series gas fryers may be optionally equipped with automatic basket lifts to ensure uniform cooking time. The lifts can be controlled manually or through a basket lift timer or Computer Magic computer. Basket lifts will always come in pairs, although each operates independently.

Each basket lift consists of a basket lift arm attached to a toothed rod, a reversible-drive gear motor, and a pair of roller-activated microswitches. The gear motor engages the teeth on the rod and moves it up or down based on the motor’s rotation. Microswitches at the upper and lower limits of movement stop the motor when the basket is fully up or down. They also reverse the direction of current ﬂ ow to reverse the motor direction. When the manually set or programmed cooking time has elapsed, the basket lift receives current and raises the basket out of the oil.

In units conﬁ gured for manual (push-button) controls, a mechanical or electrical timer controls voltage to the system. Turning a rotary knob sets the cook time, and pressing the button in the middle of the knob activates the motor. When the timer times down, power is supplied to the opposite pole of the motor through the upper microswitch. The motor drives the rod upward until it loses contact with the upper microswitch, cutting power to the motor and stopping the lift.

In units conﬁ gured for basket lift timers or Computer Magic computers, the process is almost identical. The difference is that the push button mechanical timer is replaced with timing circuitry in the computer or controller. The operator programs the speciﬁ c cook times (and other settings) into the computer or controller. When the product button is pressed, the timing circuitry activates a coil in the basket lift relay to supply power to the lower microswitch. As with the manually controlled units, the microswitches stop the motor at the lift’s upper and lower travel limits and reverse the direction of current ﬂ ow, reversing the motor’s direction.

There are three basket lift problem types. They are

• binds and jams,

• motor and gear wear, and

1-22

• electronics failure.

Binds and Jams

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.

Another possible cause of binding is the 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 Wear

The most likely problem 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. Correct the problem 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. The brake cannot be repaired and the motor must be replaced.

If the motor fails to run when power is reaching it, replace the motor because it has burned-out.

Electronics Failure

An electronics failure may be caused by relays, microswitches, capacitors, resistors, interface boards, wiring, and controls. Troubleshooting electronics is a process of verifying current ﬂ ow 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 each component for the presence of 120 VAC. Examine the diagrams on Pages 1-31 and 1-32 to identify components and wiring connection points. (See Page 1-22 for simpliﬁ ed basket lift schematics.)

1-23

1.5.2 Interpretation of Analog Controller Lights

Power light ON, heat light cycling, trouble light OFF, and melt light ON:

• If the fryer oil temperature is below 180°F (82°C), the lights indicate that the unit is operating normally.

• If the fryer oil temperature is above 180°F (82°C) and the heat light continues to cycle as if in the melt cycle, this may indicate a defective probe circuit or low incoming 12 VAC to the controller.

Power light ON, heat light ON, trouble light OFF, and melt light OFF:

• If the fryer oil temperature is above 180°F (82°C) and below the setpoint temperature, the lights indicate that the unit is operating normally.

• If the fryer oil temperature is above setpoint and the heat light remains lit, this may indicate a defective probe circuit.

Power light ON, heat light OFF, trouble light ON, and melt light OFF:

• If the fryer oil temperature is below 410°F (210°C), the lights indicate one of the following:

a. The probe circuit is defective, or

b. There is a connection problem on pins 2 or 10 on the 15-pin wiring harness.

• If the fryer oil temperature is above 410°F (210°C), the lights indicate a “run-away” heating circuit.

1.6 Probe Resistance Chart

Probe Resistance Chart

For use with 35- and 45-series fryers manufactured with Minco Thermistor probes only.

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

60 1061 16 130 1206 54 200 1350 93 270 1493 132 340 1634 171 65 1070 18 135 1216 57 205 1361 96 275 1503 135 345 1644 174 70 1080 21 140 1226 60 210 1371 99 280 1514 138 350 1654 177 75 1091 24 145 1237 63 215 1381 102 285 1524 141 355 1664 179 80 1101 27 150 1247 66 220 1391 104 290 1534 143 360 1674 182 85 1112 29 155 1258 68 225 1402 107 295 1544 146 365 1684 185 90 1122 32 160 1268 71 230 1412 110 300 1554 149 370 1694 188

95 1133 35 165 1278 74 235 1422 113 305 1564 152 375 1704 191 100 1143 38 170 1289 77 240 1432 116 310 1574 154 380 1714 193 105 1154 41 175 1299 79 245 1442 118 315 1584 157 385 1724 196 110 1164 43 180 1309 82 250 1453 121 320 1594 160 390 1734 199 115 1174 46 185 1320 85 255 1463 124 325 1604 163 395 1744 202 120 1185 49 190 1330 88 260 1473 127 330 1614 166 400 1754 204 125 1195 52 195 1340 91 265 1483 129 335 1624 168 405 1764 207

1-24

1.7 Troubleshooting Guides

The following are only guides. They are provided to assist the technician or service professional in the isolation of failures in components and wiring on the fryer.

1.7.1 Troubleshooting the 24 VAC Circuit

Troubleshooting the 24 VAC Circuit: Analog Controller

Before troubleshooting, verify that the drain valve(s) is fully closed and move the power switch into the ON position.

PROBLEM PROBABLE CAUSES

24 VAC not present at gas valve or the power switch. • Failed 24 volt transformer Continuity across the power switch not equal to 0. • Failed power switch Continuity across the thermostat not equal to 0. • Failed thermostat

• If 24 VAC is present at the gas valve, go to Troubleshooting the Gas Valve, Section 1.7.2.

Troubleshooting the 24 VAC Circuit: Electronic Ignition (Computer Controller)

Before troubleshooting, verify that the drain valve is fully closed, then turn on the controller.

PROBLEM PROBABLE CAUSES

No LEDs on the interface board are lit. • Failed 24 volt transformer

• Failed interface board

• Failed or open drain safety switch

• Failed wiring between components

24 volt LED on the interface board is lit, no others. • Failed interface board

• Failed or open drain safety switch

• Failed wiring between components

GV LED on the interface board is lit (with or without other LEDs). • Failed interface board

• Open high-limit thermostat

• Failed or open drain safety switch

• Failed wiring between interface board and gas valve

• Failed gas valve

LED 3 is continually lit, but LED 2 and LED 4 are not lit. • Failed heat relay

• Failed interface board

LEDs 2, 3, and 4 are lit, but 24 VAC is not present at V1S (V1D and V2D on dual-vat units).

LEDs 2, 3, and 4 are lit, and 24 VAC is present at V1S (V1D and V2D on dual-vat units).

• Failed igition module

• Failed interface board

• If a failed ignition module is suspected, replace the questionable module with one known to be good to isolate the problem.

• If 24 VAC is present on pin 6 on J1, but the pilot will not light, go to Troubleshooting the Gas Valve, Section 1.7.2.

• If 24 VAC is present on pin 20 of the 20-pin terminal block, but not at the gas valve, go to Troubleshooting the Gas Valve, Section 1.7.2.

1-25

Troubleshooting the 24 VAC Circuit: Standing Pilot (Computer Controller)

PROBLEM

PROBABLE CAUSES

Before troubleshooting, verify that the drain valve is fully closed, then turn on the controller.

PROBLEM PROBABLE CAUSES

No LEDs on the interface board are lit. • Failed 24 volt transformer

• Failed interface board

• Failed or open drain safety switch

• Failed wiring between components

24 volt LED on the interface board is lit, no others. • Failed interface board

• Failed or open drain safety switch

• Failed wiring between components

GV LED on the interface board is lit (with or without other LEDs). • Failed interface board

• Open high-limit thermostat

• Failed or open drain safety switch

• Failed wiring between interface board and gas valve

• Failed gas valve Continuity across drain safety switch(es) not equal to 0 • Failed or open drain safety switch. 24 VAC is not present at V1S (V1D and V2D on dual-vat units). • Failed interface board

• If 24 VAC is present all the way through to the high-limit, go to Troubleshooting the Gas Valve, Section 1.7.2.

1.7.2 Troubleshooting the Gas Valve

Before troubleshooting, verify that the gas main street valve is open and the fryer gasline cutoff valve is open. Place the gas valve in the ON position.

PROBLEM PROBABLE CAUSES

Incoming gas pressure is too high or low. • Problem with gas supply Pilot won’t remain lit, low millivolt output from thermopile. • Failed thermopile Pilot won’t remain lit, good millivolt output from thermopile. • Failed gas valve

• Failed high-limit

• If 24 VAC is not present at the gas valve, go to Troubleshooting the 24 VAC Circuit, Section 1.7.1.

1.7.3 Troubleshooting the Thermostat

Check the calibration of the thermostat before troubleshooting, if possible.

PROBLEM

The burner does not light when the thermostat is set to the maximum setting.

• Failed thermostat

• Failed wiring

PROBABLE CAUSES

• If 24 VAC is present at the gas valve, but the burner is not lighting, go to Troubleshooting the Gas Valve, Section 1.7.2.

1-26

1.7.4 Troubleshooting the Temperature Probe

Follow these guidelines to troubleshoot the temperature probe:

1. While it is still in the frypot, inspect the probe body for damage. Inspect the leads for fraying, burning, breaks, or kinks. If the probe is bent, dented, or cracked, or if the leads are damaged, replace the probe.

2. Determine the temperature of the cooking oil using a thermometer or pyrometer placed at the tip of the probe.

3. Disconnect the 15-pin wiring harness from the interface board. Measure the probe resistance using J2 pins 13 and 14.

5. If the resistance matches the corresponding temperature on the chart, measure the resistance through J2 pin 13 and ground. Then, through J2 14 and ground. If the resistance of each pin is 5 megaohms or greater, the probe is working correctly. If the resistance is less than 5 megaohms, it has failed and must be replaced.

1-27

1.8 Wiring Diagrams

1.8.1 Standing Pilot

1-28

1.8.2 Electronic Ignition

1-29

1.8.3 Non-Computer Controlled Fryer

1-30

1.8.4 Electronic Ignition

1-31

1.8.5 Filter Box

8050902D

1-32

1.8.6 Modular Basket Lift 100/120V



1-33

1.8.7 Modular Basket Lift 208/250V

12 - - - - - 7

1-34

PERFORMANCE PRO SERIES GAS FRYERS MODELS 35 & 45

CHAPTER 2: PARTS LIST

2.1 Accessories

ITEM PART # COMPONENT

1 810-2793 Wireform Basket Hanger * 106-2186 Basket Hanger, Burger King * 823-4447 Basket Hanger, Buffalo Wild Wings® and Jack in the Box * 823-1462 Basket Hanger, Checkers * 106-2185 Basket Hanger, Checkers®, Bracket 2 809-0171

Basket Hanger Screw (basket hanger spacer, 809-0921)

* 803-0099 Basket, Full 3 803-0271 Basket, Twin * 803-0190 Basket, Twin, Buffalo Wild Wings * 803-0357 Basket, Triple 4 803-0132 Wire Basket Support Rack, Full-vat (MJ 45) 5 803-0133 Wire Basket Support Rack, Dual-vat * 803-0032 Wire Basket Support Rack, without Notches (MJ 35) * 803-0136 Basket Support Screen (MJ 45) * 803-0037 Basket Support Screen (MJ 35) 6 810-0088 Flexible Gas Line, 1-36 * 810-0084 Flexible Gas Line, ¾-48 7 810-0073 Quick Disconnect Fitting, 1” Female 8 810-0074 Quick Disconnect Fitting, 1” Male * 803-0188 Sediment Tray, Full-vat (MJ 35) * 803-0103 Sediment Tray, Full-vat, (MJ 45) * 803-0107 Sediment Tray, Dual-vat, Left (MJ 45) * 803-0108 Sediment Tray, Dual-vat, Right (MJ 45) 9 806-5518 Cover, Frypot or Holding Station, Full-vat * 806-3232 Cover, Frypot or Holding Station, Dual-vat

10 826-0993SP Handle Kit, Frypot Cover

* 826-1351 Nut Retainer, ¼-20 Nutsert (pkg. of 10) 11 803-0197 Fryer Friend (Clean-out Rod), 27” 12 803-0209 Brush, Frypot 13 803-0278 Brush, L-Shaped 14 823-3660 Crumb Scoop 15 823-5936 Splash Guard, Right 16 823-5937 Splash Guard, Left

* OPT32686 Foodwarmer (with scoop pan)

* 806-6988SP Foodwarmer Kit

* 106-4786 Spreader Storage Pan

* 910-3557

* 826-1017

* KIT3647

Flue Deﬂ ector (See Section 2.6 for more information and associated items.) Screw Kit, Flue Deﬂ ector (See Section 2.6 for more information and associated items.)

Applebee’s

Heat Lamp (available as OPT33030 for MJ 45 only)

* Not illustrated.

2-1

2.2 Basket Lift and Associated Parts

19 13 11

20 14 25

16 10 26

NOTES:

1. Assemblies 106-1807SP (100-120V) and 106-1810 (230/240/250V) do not

include Items 1, 2, 3, 9, or 17. These items must be ordered separately.

2. For 100-120V units, each individual resistor (807-2661) may be replaced

or the entire resistor assembly (806-8530SP) may be replaced.

3. For 208-250V units, the entire resistor assembly (106-2771 or 806-9185)

must be replaced.

4. Wiring has been omitted for clarity.

14 23

22 15 12

13 11 25

Before (11/02)

100-120V Configuration

2-2

(After 10/02)

208-250V Configuration

ITEM PART # COMPONENT

1 910-4776 Enclosure, Stainless Steel

* 900-4776 Enclosure, Cold-rolled Steel

* 826-1991 Kit, Cold-rolled Steel Enclosure (with 12 screws)

2 823-7062 Basket Lift Arm, Left

3 823-7064 Basket Lift Arm, Right

4 901-8499 Chassis, Left

5 902-8499 Chassis, Right

6 200-2942 Mount, Basket Lift

7 809-0082 Truarc Retaining Ring, ¾”

8 826-1361 Screw, 8-32 x 1” Slotted Truss Head (pkg. of 25)

9 809-0127 Screw, ¼-20 x ½” Slotted Round Head

10 809-0186 Lock Washer with External Teeth, #8 11 826-1366 Nut, 4-40 Hex Keps with External Tooth (pkg. of 25) 12 809-0247 Nut, 8-32 Hex Keps 13 826-1359 Screw, 4-40 x ¾” Slotted Round Head (pkg. of 25) 14 826-1371 Screw, #8 x ½” Hex Head Drill Point (pkg. of 25) 15 826-1374 Screw, #10 x ½” Hex Head (pkg. of 25) 16 809-0503 Screw, 8-32 x ½” Hex Head 17 810-0172 Plug, Stainless Steel, ⅝” Hole 18 810-1012 Toothed Rod, Basket Lift 19 812-0442 Insulation, Microswitch 20 813-0035 Bushing, Bronze, .640” ID 21 816-0033 Ty Wrap, Screw Mount 22 900-5529 Gusset, Basket Lift Motor 23 807-2513 Capacitor, Motor 24 807-2572 Microswitch 25 Resistor Assembly

806-8530SP 100-120V

106-2771 208-250V

26 806-5964SP Gear Motor Assembly

810-1013 Gear 809-0504 Set Screw 810-0973 Woodruff Key

27 806-9257SP Roller Guide/Bracket Assembly

Basket Lift Assemblies

* 106-1807SP 100-120V (without relay)

* 106-1810SP 208-250V

* KIT6421 Complete 120V Basket Lift Assembly for FPP35/45

* KIT7193 Complete 230V Basket Lift Assembly for FPP35/45

* KIT7413 Complete 230V Basket Lift Assembly for PMJ35

* 807-3699 Harness, Basket Lift

28 824-1476 Drip Pan, Left 29 824-1477 Drip Pan, Right

* 200-8862 Drip Plate/Shield

* Not illustrated.

** Diagrams on Pages 1-22, 1-31, 1-32 in Chapter 1.

2-3

2.3 Cabinetry

2.3.1 FPP/FMP Model Cabinetry

Front of fryer.

Rear of fryer.

Four station fryer shown.

2-4

ITEM PART # COMPONENT

Cabinet Assemblies (see Section 2.3.3)

106-9088 106-9090 106-9092 106-9094 106-4525 Applebee’s

Two Station Fryer, Stainless (106-9089, Cold Rolled Steel) Three Station Fryer, Stainless (106-9091, Cold Rolled Steel) Four Station Fryer, Stainless (106-9093, Cold Rolled Steel) Five Station Fryer, Stainless (106-9095, Cold Rolled Steel)

Dump Station

Base Assemblies

106-3785 Two Station Fryer 106-4019 Three Station Fryer 106-4020 Four Station Fryer 106-4021 Five Station Fryer

Brace, Top Cabinet

900-7730 Two Station Fryer 900-9430 Three Station Fryer 900-9318 Four Station Fryer 200-5474 Five Station Fryer

Back Panels, Upper (Use with cabinet assemblies.)

200-6901 Use with 106-3783, 106-4017, 106-4018, 106-4031, 106-4033, 106-4034. 200-6906 Use with 106-4016, 106-4018, 106-4032, 106-4034. 210-6608 Use with 106-3783, 106-4017, 106-4018. 210-6895 Use with 106-4016, 106-4018.

Back Panels, Lower

200-6905 Use with 106-3783, 106-4017, 106-4018, 106-4031, 106-4033, 106-4034. 200-6908 Use with 106-4016, 106-4018, 106-4032, 106-4034. 210-6897 Use with 106-4016, 106-4018. 210-6874 Use with 106-4034, 106-4032, 106-4016, 106-4018. 200-8567

211-6893 211-6933

212-6893 212-6933

Use with 106-4525 (Applebee’s® Dump Station). Side, Left Cabinet

Side, Left Cabinet, Stainless Steel (201-6917, Cold Rolled Steel) Side, Left Cabinet, Stainless Steel with hole (201-6934, Cold Rolled Steel)

Side, Right Cabinet

Side, Right Cabinet, Stainless Steel (202-6917, Cold Rolled Steel) Side, Right Cabinet, Stainless Steel with hole (202-6934, Cold Rolled Steel)

Other Components

* 220-0927 Heat Shield, Filter, Buffalo Wild Wings (220-0928, Third Vat)

* 200-6908 Back, Lower Cabinet, Aluminized (three and ﬁ ve station fryers)

* 210-6897 Back, Lower Cabinet, Stainless Steel (three and ﬁ ve station fryers)

5 200-2235 Bracket, Component Box

6 200-1953 Brace, Front Cabinet

7 200-6057 Brace, Cabinet Cross

8 200-6062 Support, Upper Rear Cabinet

9 200-6310 Support, Rear Cabinet Rail 10 200-6346 Gusset, Rear Cabinet 11 200-6486 Brace, Front Cross 12 200-6892 Post, Front Door Long 13 200-6894 Post, Rear Cabinet Long 14 200-6911 Post, Front Cabinet Long 15 826-1389 Screw, ¼-20 x ¾” Hex Head (pkg. of 10)

* 910-7443 Top Connecting Strip, Frypot

* 910-6650 Channel, Top Connecting Strip

* 823-1885 Top Connecting Strip and Channel, Burger King

* 910-4617 Top Connecting Strip, Fryer-to-Spreader 16 826-1374 Screw, #10 x ½” Washer Hex Head (pkg. of 25) 17 809-0417 Nut, Flange 18 823-4727 Hinge Assembly, Left Upper

* Not illustrated. ** Four station fryers use two backs made for two station fryers. Five station fryers use two backs: a three station fryer back and a two station fryer back.

FPP/FMP Model Cabinetry continued on next page...

2-5

ITEM PART # COMPONENT

19 823-4728 Hinge Assembly, Right Upper 20 823-4745 Hinge Assembly, Left Lower 21 823-4746 Hinge Assembly, Right Lower 22 220-4180 23 106-9083

Rail Assembly, Left (nut separate: 809-0495) Rail Assembly, Right (nut included)

24 222-4183 Rail, RH Filter Pan Retaining 25 221-4483 Rail, LH Filter Pan Retaining 26 220-4182 Rail, Slide

* 200-6935 Stop, Filter Rail 27 900-7326 Divider

* KIT0293 Joiner Kit, Applesbee’s

Dump Station

* 210-9291 Top Connecting Strip, Fryer-to-Fryer 28 809-0193 Nylon Washer

* 810-2346 Magnet, Door

Garland Range Cabinetry (See Section 2.19, Garland Range)

* Not illustrated.

2.3.2 PMJ (Non-ﬁ lter) Model Cabinetry

Front of fryer.

Rear of fryer.

Four station fryer shown.

2-6

ITEM PART # COMPONENT

Cabinet Assemblies

106-4028 106-4036 106-4037 106-4038 106-4039 106-4525 Applebee’s

106-5440 Single Station Fryer 106-4040 Two Station Fryer 106-4041 Three Station Fryer 106-4042 Four Station Fryer 106-4043 Five Station Fryer

200-6903 Use with 106-4030, 106-4028. 200-6904 Use with 106-4030, 106-4028. 210-6817 Use with 106-4028. 210-6818 Use with 106-4028. 200-5867 Use with 105-4525 (Applebee’s

200-6901 Use with 106-4036, 106-4038, 106-4039, 106-4051, 106-4053. 200-6902 Use with 106-4036, 106-4051, 106-4053. 200-6906 Use with 106-4037, 106-4039, 106-4052. 200-6907 Use with 106-4052, 106-4037. 210-6608 Use with 106-4036. 106-4038. 106-4039. 210-6895 Use with 106-4037, 106-4039. 210-6896 Use with 106-4037. 210-6650 Use with 106-4036, 106-4038.

200-6905 Use with 106-4036, 106-4038, 106-4039, 106-4051, 106-4053. 200-6908 Use with 106-4037, 106-4039, 106-4052. 210-6874 Use with 106-4037, 106-4039, 106-4052. 210-6897 Use with 106-4037, 106-4039.

900-4813 Single Station Fryer 900-7730 Two Station Fryer 900-9430 Three Station Fryer 900-9318 Four Station Fryer 200-5474 Five Station Fryer

211-6893 211-6933

212-6893 212-6933

Single Station Fryer, Stainless (106-4030, Cold Rolled Steel) (806-6741 Garland) Two Station Fryer, Stainless (106-4051, Cold Rolled Steel) Three Station Fryer, Stainless (106-4052, Cold Rolled Steel) Four Station Fryer, Stainless (106-4053, Cold Rolled Steel) Five Station Fryer, Stainless (106-4054, Cold Rolled Steel)

Base Assemblies

Back Panels, Single

Back Panels, Upper (Use with cabinet assemblies.)

Back Panels, Lower (Use with cabinet assemblies.)

Brace, Top Cabinet

Side, Left Cabinet

Side, Left Cabinet, Stainless Steel (201-6917, Cold Rolled Steel) Side, Left Cabinet, Stainless Steel with hole (201-6934, Cold Rolled Steel)

Side, Right Cabinet

Side, Right Cabinet, Stainless Steel (202-6917, Cold Rolled Steel) Side, Right Cabinet, Stainless Steel with hole (202-6934, Cold Rolled Steel)

Dump Station

Other Components

* 200-6908 Back, Lower Cabinet, Aluminized (three and ﬁ ve station fryers) * 210-6897 Back, Lower Cabinet, Stainless Steel (three and ﬁ ve station fryers) 5 200-2235 Bracket, Component Box 6 200-1953 Brace, Front Cabinet

7 200-6057 Brace, Cabinet Cross 8 200-6062 Support, Cabinet upper Rear 9 200-6346 Gusset, Rear Cabinet

* Not illustrated.

Four station fryers use two backs made for two station fryers. Five station fryers use two backs, a three station fryer back with a two

station fryer back.

PMJ (Non-ﬁ lter) Model Cabinetry continued on next page...

2-7

ITEM PART # COMPONENT

10 200-6486 Brace, Front Cross 11 200-6894 Post, Rear Cabinet Long 12 200-6911 Post, Front Cabinet Long 13 826-1374 Screw, #10 x ½” Washer Hex Head (pkg. of 25) 14 823-4727 Hinge Assembly, Left Upper 15 823-4728 Hinge Assembly, Right Upper 16 823-4745

Hinge Assembly, Left Lower (823-4713 on single fryers)

17 823-4746 Hinge Assembly, Right Lower 18 900-7326 Divider

* KIT0293 Joiner Kit, Applesbee’s

* 20

810-1105 Magnet, Door - Single Fyer 809-0193 Nylon Washer

Dump Station

* Not illustrated.

2.4 Casters, Legs, and Associated Hardware

ITEM PART # COMPONENT

Legs

810-3169 Legs (pkg. of 4) 810-3168 Leg, Individual

2 826-1095 Anchor Strap Kit

Casters

3 810-0357 Caster, 5” Swivel with Brake (with hardware, 826-1118)

4 810-0356 Caster, 5” Swivel without Brake (with hardware, 826-1117)

5 810-0378 Caster, 5” Rigid

6 810-0651 Caster, 3” with Brake, Filter Cabinet (with hardware, 826-1130)

* 810-0750 Caster, 5” Rigid (PMJ units)

7 826-0900 Chain Restraint Kit

* 826-1113 Fastener Kit (one per caster or leg)

* Not illustrated.

2-8

Full-vat Component Box Assembly

[with Melt Cycle Timer]

Full-vat Component Box Assembly

[Standing Pilot]

Full-vat Component Box Assembly

[Electronic Ignition]

2.5 Component Boxes

(Illustrations may differ slightly from actual boxes depending upon the conﬁ guration of the fryer.)

2-9

ITEM PART # COMPONENT

1 807-0670 Relay, 24V 2 807-0833 Relay, Latch * 807-0834 Relay, Basket Lift 3 200-7176 Bracket, Relay 4 810-2243 Spring, Relay Hold Down 5 816-0217 Insulating Paper 6 810-1164 Terminal Block, 1 Plc. Screwless Terminal 7 810-1168 Terminal Block, Screwless End 8 826-1337 Tab, Terminal (pkg. of 5) 9 806-5857 Interface Board, Electronic Ignition

10 826-2425 Interface Board, Pilot Ignition

11 826-1546 Melt Cycle Timer Kit 12 810-0045 Bushing, .875 13 Transformers

807-0800 120V/24V 807-2176 100-120V/12V & 24V 807-0680 208-240V/12V & 24V 807-1999 208-240V/24V, 208-250V/12V & 24V

14 807-5244 Ignition Module, Fenwal

* 826-2898 Kit to replace Honeywell module with Fenwal (807-5244) * 806-5879SP Cable Assembly, Ignition Module, Interface Board to Module * 806-5830SP Cable, Ignition, with Ceramic Cover * 807-3483 Cable, Ignition (used with MJ45 ignition cable kit, 826-1721) * 807-4375 Connector, Rajah * 807-1928 Flame Sensor Electrode * WIR0165 Component Shield (Std.) Wiring (FV, 208-250 Export only) * 809-0349 Spacer, Interface Board * 826-1346 Spacer, Ignition Module (pkg. of 10) * WIR0148 Component Shield (with Mechanical Timer) Wiring * WIR0161 Component Shield (with Melt Cycle) Wiring (DV) * WIR0164 Component Shield (with Melt Cycle) Wiring (FV, 240V and below) * WIR0160 Component Shield Wiring (DV) * WIR0163 Component Shield Wiring (FV) * WIR0162 Component Shield Wiring (FV, DV) * WIR0258 Wiring, Component Shield * WIR0329 Component Shield Drainswitch Wiring (DV/FV) * WIR0349 Microswitch Wiring (DV) * WIR0350 Microswitch Wiring (DV)

* Not illustrated.

2-10

2.6 Control Panel Assemblies, Flue Caps, and Related Items

3 2

11 6

2-11

ITEM PART # COMPONENT

Control Panel Assemblies

1 108-1550 Single Station Fryer 2 108-1551 Two Station Fryer 3 108-1552 Three Station Fryer 4 108-1553 Four Station Fryer 5 108-1554 Five Station Fryer * 106-4535 Applebee’s

Control Panel

Flue Caps

PMJ 45 6 210-6812 Single Station Fryer 7 106-4012 Two Station Fryer 8 106-4013 Three Station Fryer 9 106-4014 Four Station Fryer

10 106-4015 Five Station Fryer

PMJ 35

11 210-6811 Single Station Fryer 12 106-4008 Two Station Fryer 13 106-4009 Three Station Fryer 14 106-4010 Four Station Fryer 15 106-4011 Five Station Fryer

Burger King/Checkers

16 106-4184 17 106-4185 18 106-4186 19 106-4187

Two Station Fryer (with buttons, 106-4188) Three Station Fryer (with buttons, 106-4189) Four Station Fryer (with buttons, 106-4190) Five Station Fryer (with buttons, 106-4191)

* 824-1440 Applebee’s® Dump Station Flue Cap

20 910-3557 Deﬂ ector, Flue, 2 holes (910-3207, Deﬂ ector, Flue, 3 holes)

* 900-3933 Heat Shield, Flue * 826-1017 Screw Kit, Flue Deﬂ ector

21 900-4253 Retaining Strip, Flue Cap 22 200-6584 Support, Flue Cap

* 220-0810 Flue Guard, Panda Express

Top Cap

23 824-1409 Single Station Fryer 24 824-1410 Two Station Fryer 25 823-4940 Three Station Fryer 26 823-4941 Four Station Fryer 27 823-4942 Five Station Fryer

* 823-4990 Applebee’s® Top Cap

Control Panel Assembly with Thermostat Access Door (MJ 35)

28 106-4050 Complete, with Toggle Switch 29 106-4049

Complete, without Toggle Switch (see also 106-7449)

Thermostat Access Door (MJ 35)

30 106-4386SP Toggle Switch Assembly 31 824-1394 Switch Guard 32 210-6930 Door Panel 33 210-8289 Frame, with Toggle 34 210-6832 Frame, without Toggle

* 106-4235SP Control Panel, MV with Mechanical Timer (FPP) * 210-7026 Control Panel, Spreader Cabinet (FPP)

35 210-6946 Control Panel, with toggle swtch holes (PMJ)

* 210-8686 Control Panel, without toggle switch holes (PMJ)

* Carl’s Jr. Risers (see instruction sheet 819-6443 for installation instructions)

826-2626 Flue Cap, Single 826-2627 Flue Cap, 2-vat 826-2628 Flue Cap, 3-vat

826-2629 Flue Cap, 4-vat * 809-0171PK Thumbscrew * 826-1351 Cage Nut

* Not illustrated.

2-12

2.7 Controller Assemblies

SOLID STATE

ITEM PART # COMPONENT

Computer Magic III.5

823-2327 Full-vat (CE, 826-2328) 826-2390 Dual-vat (CE, 826-2391) 106-7248 On-hood Remote Computer (FV, MJ 45) 826-2280 In-hood Remote Computer (FV, MJ 45)

Buffalo Wild Wings

826-2409 826-2408 826-2449

Red (overlay, 807-4642) White (overlay, 807-4644) Violet (overlay, 807-4643)

Basket Lift Timer

Computer

826-2393 Full-vat (CE, 106-4172) 106-4171 Dual-vat (CE, 106-4173)

Digital Controller

826-2394 Full-vat (CE, 106-4176) 106-4175 Dual-vat (CE, 106-4175)

Solid State (Analog Controller)

106-3375 Dual-vat 106-3369

Full-vat (overlay, 807-0847)

810-0387 Knob

Controller Bezel

Computer * 210-5046 Single Station Tab Mount (Use 230-7091 for Screw Mount 09/08) * 210-5819 Two Station Tab Mount (Use 230-7092 for Screw Mount 09/08) * 210-6698 Three Station Tab Mount (Use 230-7093 for Screw Mount 09/08)

No Computer * 210-6960 Single Station Fryer * 210-6961 Two Station Fryer * 210-6962 Three Station Fryer

* 210-6766 Applebee’s * 210-7002

Blank Bezel, Single (Applebee’s

Spreader

spreader, 210-8578)

* 210-7026 Blank Bezel, 2-vat unit * 806-3660

Sound Device (SMT, 810-3141, with 2-pin connector)

* 806-4797 Buzzer * 806-2071 Controller Harness * 807-4199 Controller Harness, SMT (Remote, 807-4397)

* Not illustrated.

2-13

WIRING ASSEMBLIES, HARNESSES, AND REMOTE CABLE ASSEMBLIES

Wiring Assemblies and Harnesses

806-2079SP 100-120V Basket Lift Universal Motor (6-Pin female w/6 wires plus 1 separate wire) 806-8555SP 208-240V Modular Basket Lift Motor (6-Pin female w/6 wires plus 4 separate wires) 106-1822SP 100-120V Modular Basket Lift Motor (12-pin female w/5 wires) 106-1804SP 208-250V Modular Basket Lift Motor (12-pin female w/5 wires plus 3 separate wires) 806-4798SP Basket Lift Power, Non-CE (6-pin male w/6 wires; connects to 806-2079SP or 806-8555SP) 806-6708SP Basket Lift Power, CE (6-pin male plus 806-4798) 807-3699 Basket Lift Power, Non-CE/CE (12-pin male w/6 wires, connects to 106-1822SP or 106-1804SP) 68” 806-9777SP Thermostat Control Universal (control panel-end connections) 806-9778SP Thermostat Control Universal (component shield-end connections) 806-9779SP Basket Lift Universal (control panel-end connections) 806-9780SP Basket Lift Universal (basket lift-end connections) 806-9781SP Wiring Bundle, Component Shield to Controller and Fryer Components (21-wire bundle) 826-1560 Kit, 45 Series Wiring (contains 806-9777SP through 806-9781SP) 806-3549SP Interface Board (interface board to fryer components; 12-pin male w/5 wires) 806-6705SP CE Non-Direct Wiring Power Supply (power cords joined in junction box) 806-4214SP Fryer to Fryer Drain Safety Switch (2-pin male w/two wires and 2-pin female w/two wires) 806-4215SP Fryer to Filter Drain Safety Switch (2-pin male w/two wires and 2-pin female w/two wires)

NOTE: Assemblies 806-2079SP, 806-9777SP through 806-9781SP and kit 826-1560 are “universal” in

nature. That is, they contain all wires and connectors necessary for all conﬁ gurations of the application described. Consequently, there may be “extra” wires that are not needed in a particular conﬁ guration. Any extra wires should be removed when the assemblies are installed to preclude later confusion.

Remote Computer/Controller to Interface Board Cables

Each of these assemblies has two 15-pin male connectors, and a 15-wire cable looped through a ferrite ring.

Only the length of the cable varies.

806-2071 1.0 foot (30.5cm) (For fryer mounted computer.) 806-3383 15.0 feet (4.6m) 806-3388 20.0 feet (6.1m) 806-4318 30.0 feet (9.1m)

Remote Computer/Controller Cable Assemblies

Each of these assemblies has one 15-pin male connector, one 15-pin female connector, and a 15-wire cable.

Only the length of the cable varies.

806-3528 7.5 feet (2.3m) 806-3529 8.5 feet (2.6m) 806-3530 10.5 feet (3.2m) 806-3531 12.6 feet (3.8m)

Remote Computer/Controller Cable Assemblies w/Junction Box and Mounting Bracket

Each of these assemblies consists of a 4 X 4-inch junction box and mounting bracket assembly with one to four

15-pin female connectors and one to four 15-wire cables with a 15-pin male connector on the free end of each

cable.

806-8350 One Computer/Controller 806-8349 Two Computers/Controllers 806-8348 Three Computers/Controllers 806-8351 Four Computers/Controllers

2-14

2.8 Door Assembly

ITEM PART # COMPONENT

* 106-3965

Door Assembly

1 230-4960 Handle 2 210-6739 Pin, Door Hinge 3 809-0266 Screw, #10 x ½” Phillips Truss Head 4 826-1343 Spring, Door Hinge Lock 5 232-4707 Hinge, Lower, Right * 231-4707 Hinge, Lower, Left * 810-2346 Magnet, Horizontal Mount (white) * 106-3931 Door, Applebee’s

Filter/Dump Station

* Not illustrated.

2-15

2.9 Drain System Components

2.9.1 Drain Tube System

ITEM PART # COMPONENT

Drain Tubes

1 Tube, Left/Right End Short

823-4625 Full-vat 823-4624 Dual-vat

2 Tube, Left/Right Open Short

823-4643 Full-vat 823-4642 Dual-vat

3 Tube, Right End Long

823-4639 Full-vat 823-4638 Dual-vat

4 Tube, Left/Right Open Long

823-4641 Full-vat

823-4640 Dual-vat * 200-6473 Spreader, Open Long * 200-6474 Spreader, Open Short 5 823-4740 Drain Outlet, Both Ends Open

823-4741 Drain Outlet, One End Closed

Miscellaneous

6 816-0729 Boot 7 809-0969 Clamp * 807-2484 Solenoid * 811-0932 Tubing, ⅜” O.D., Plastic * 810-1372 90° Fitting, ⅜” O.D. * 811-1071 Tubing, ¼” O.D., Plastic * 810-2493 90° Fitting, ¼” O.D. * 810-2492 Straight Fitting, ¼” O.D. * 816-0630 Vinyl Stud Cap 8 809-0047 Nut, High Proﬁ le Stud Cap * KIT6214 Round Drain Boot Kit (includes 2 clamps and 1 boot)

* Not illustrated.

2-16

2.9.2 Drain Valves; FPP/FMP Models

Compression Washers

Flat Washers

Flat Washer

Plastic Washer

Dual-vat, Left Assembly 106-3999

Plastic Washer

Full-vat Assembly 106-3760

Dual-vat, Right Assembly

106-4000

2-17

Compression Washers

Flat Washer

ITEM PART # COMPONENT

Drain Valve Assemblies

106-3760 Full-vat

106-3999 Dual-vat, Left

106-4000 Dual-vat, Right

Drain Valves

1 810-1018 Full-vat, 1.25-inch Drain Valve (without Handle) 2 810-1114 Dual-vat, 1-inch Drain Valve

Drain Safety Switch

3 807-2103 Microswitch 4 816-0220 Insulation 5 901-2348 Cover

Bracket 6 806-8137 Full-vat 7 106-2671 Dual-vat, Left 8 106-2672 Dual-vat, Right

Miscellaneous

9 200-6496 Support, Drain Tube

10 900-2936 Retainer Nut (FV)

* 900-2934 Retainer Nut (DV)

11 809-0540 Nut, 2-way Lock (FV) 12 809-0539 Nut, 2-way Lock (DV) 13 826-0237 Nut, 4-40 Keps Hex with External Tooth (pkg. of 25)

Handle, Valve

14 824-1602 Full-vat 15 824-1637 Dual-vat, Left 16 824-1636 Dual-vat, Right 17 816-0639 Sleeve, Handle 18 816-0135 O-ring 19 810-1165 Washer, Teﬂ on 20 809-0196 Washer, Flat

2-18

2.9.3 Drain Valves; PMJ Models

Full-Vat

Dual-Vat Left Dual-Vat Right

ITEM PART # COMPONENT

1 810-1569 Valve, 1.25-inch, Non-ﬁ lter, Full-vat Drain (with handle) 2 806-7915SP Valve, 1-inch, Non-ﬁ lter, Dual-vat, Left Drain 3 806-7916SP Valve, 1-inch, Non-ﬁ lter, Dual-vat, Right Drain * 810-1338 Valve, 1-inch, Universal Ball * 806-9062 Handle, Left * 806-9064 Handle, Right 4 812-1226SP Drain Extension, 1.25-inch, Full-vat * 812-1227 Drain Extension, 1-inch, Dual-vat 5 810-1427 Handle, Drain Valve 6 810-1568 Handle, Drain Valve * 816-0211 Sleeve, Handle

* Not illustrated.

2-19

2.10 Filter Boxes

120V Assembly

(106-3981)

208-240V Assembly

(106-3989)

208-250V Assembly

(106-3988)

2-20

ITEM PART # COMPONENT

Complete Box Assemblies

106-3981 106-3988 208-250V 106-3989 208-240V

1 200-6836 Filter Box 2 200-6837 Lid 3 200-6838 Mount 4 806-7494 Plug Assembly, Non-Reversing * 810-1421 Harness (to Control Circuits) 5 806-8021 Plug Assembly, Heater Plug 6 807-0012 Relay, 18 Amp 7 807-0141 Connector, ⅜” Right Angle 8 Transformers

807-0800 120V/24V 807-0680 208-240V/24V 807-1999 208-250V/12V & 24V

9 810-1164 Terminal Block, 1 Plc Screwless 10 812-1704 Conduit, Flex ⅜” x 13.5” 10 812-0636 Conduit, Flex ⅜” x 15” 11 816-0217 Paper, Insulation 12 826-1366 Nut, 4-40 Keps Hex with External Tooth (pkg. of 25) 13 826-1359 Screw, 4-40 x ¾” Slotted Round Head (pkg. of 25) 14 809-0360 Screw, #8 x ⅜” Washer Slotted Hex Head

* 810-1421 Harness, Control Circuit

* Not illustrated.

120V (see also 806-6912)

Components

2-21

2.11 Filter Pan Assembly

ITEM PART # COMPONENT

1 108-0184SP Filter Pan No Rollers July 2008 (Use 106-3796SP Pan with Rollers)

2 810-3161 Crumb Tray

* 813-0568 Plug, ⅛” Socket-head Pipe

3 826-1372 Nut, Grip ¼-20 Hex (pkg. of 10)

* 826-1392 O-ring

4 810-2198 Roller, Filter Pan Rail

* 809-1025 Nylon Slides

* 826-2603 Rail Set, Filter Pan Rail

* 826-1979 Kit, Filter Pan Roller

* 809-0191 Washer, Spring Lock, ¼”

5 812-2024 Screen, Sana Grid

6 810-3760

7 823-6412

Ring, Hold Down (810-2910, FMP, see also 810-3760) Lid, Filter Pan, FPP (included in kit 826-2109, 826-2110, and 826-2111)

* 823-5334 Lid, Filter Pan, FMPH

8 823-5294

Splash Shield (included in kit 826-2109, 826-2110, and 826-2111)

9 106-5141 Bracket, Burner Heat Shield Mounting (MJ35) 10 809-0173 11 200-9732 12 200-9715

Clip, Tinnerman (included in kits 826-2109, 826-2110, and 826-2111) Lip, Suction Fitting (included in kits 826-2109, 826-2110, and 826-2111) Brace, Drain Spout (included in kits 826-2110 and 826-2111)

13 826-1371 Screw, #8 x ½” Hex Head Drill Point (pkg. of 25) 14 809-0785 Screw, #14 x ¾” Slotted Head

* 200-6310 Support, Rear Pan Rail

* 809-0743 Screw, 4-40 x 1 Pan Head, Stainless Steel

* 803-0170 Filter Paper, 19.5 x 25.5 (box of 100 sheets)

* 803-0002 Filter Powder (box of 80 individual packs)

* 810-2800 Carl’s Jr. Filter Leaf

* 816-0757 O-ring, Optional Filter Leaf

* Not illustrated.

2-22

2.12 Frypots

MJ45, Full-vat, SS

MJ45, Dual-vat, SS

MJ35, Full-vat, SS

(Front Flush)

MJ45, Full-vat, SS

(Front Flush)

5 6

MJ45, Dual-vat, SS

(Front Flush)

ITEM PART # COMPONENT

PMJ 35

1 106-4115SP Full-vat, Stainless Steel, (Power Shower)

* 106-9776 Full-vat, Stainless Steel, Single Non-ﬁ lter For XMJ135V

* 823-4492SP Full-vat, Stainless Steel (Pre-Pro MJ35)

2 106-8362SP Full-vat, Stainless Steel (Front Flush) Service Part

* 106-7671SP Full-vat, Stainless Steel (Power Shower) Export

* 106-9727SP Full-vat, Stainless Steel (PMJ) Non-Filter Service Part

* 106-8363SP Full-vat, Stainless Steel (Domestic, Power Shower) Service Part

PMJ 45

3 106-2547SP Full-vat, Stainless Steel (Power Shower) Service Part FP47 only

4 106-2545SP Dual-vat, Stainless Steel FP47

5 106-5868SP Full-vat, Stainless Steel (Front Flush) Service Part FPP45

6 106-5869 Dual-vat, Stainless Steel (Front Flush)

* 106-7681SP Full-vat, Stainless Steel (Power Shower) Service Part FPP45

* 106-7740 Dual-vat, Stainless Steel (CE)

* Not illustrated.

** Frypots listed above include insualtion and other necessary components. See Section 2.13.

2-23

2.13 Frypot Cabinetry

2.13.1 PMJ45 Frypot Cabinetry

Frypot assemblies located in Section 2.12.

ITEM PART # COMPONENT

1 806-5778SP Flue Deﬂ ector Box Assembly

2 826-1374 Screw, #10 x ½” Washer Hex Head

3 806-5567SP Flue Assembly, MJ45

4 806-1095SP Front Bafﬂ e Assembly

* 106-5874 Front Bafﬂ e Assembly (Front Flush Full-vat)

* 106-5892 Front Bafﬂ e Assembly (Front Flush Dual-vat)

5 809-0409 Screw, Pilot Light Cover

6 810-0647 Holder, Pilot Light Cover Screw

7 108-0442

Cover with Sight-glass, Pilot Light (without sight-glass, 900-1090)

8 806-5566SP Rear Combustion Chamber Panel Assembly

9 806-1097 Side Combustion Chamber Panel Assembly

10-13 826-0861

Kit, Insulation (cut to ﬁ t)

* 816-0658 Insulation Back, Lower Single

* 816-0656 Insulaiton Back, Upper Single 14 809-0173 Clip, Tinnerman 15 809-0170 Screw, #14 x ¾” Slotted Pan Head

* 210-0681 Probe Guard

* 816-0698 Insulation, Kaowool Blanket (Front Flush)

* 220-0927 Air/Heat Shield, 31”

* 220-0928 Air/Heat Shield, 15 ½”

* 813-0463

* Not illustrated.

Pipe Plug, 1/2” NPT

2-24

2.13.2 PMJ35 Frypot Cabinetry

Frypot assemblies located in Section 2.12.

All insulation is included in 826-0861 and should be cut to fit.

ITEM PART # COMPONENT

1 106-8274SP Flue Assembly, MJ35

2 900-3267 Flue Deﬂ ector Box Assembly

3 806-4168SP Combustion Chamber, Front

* 806-4168 Front Bafﬂ e Assembly (Front Flush Full-vat)

4 809-0409 Screw, Pilot Light Cover

5 810-0647 Holder, Pilot Light Cover Screw

6 108-0442

Cover with Sight-glass, Pilot Light (without sight-glass, 900-1090)

7 900-6204 Combustion Chamber, Side

* 826-0861

Kit, Insulation (cut to ﬁ t)

* 812-0134 Insulation, Frypot Upper Side

* 816-0658

* 816-0656

Insulation, Frypot Lower Back (Singles) Insulation, Frypot Upper Back (Singles)

8 826-1374 Screw, #10 x ½” Washer Hex Head

9 809-0173 Clip, Tinnerman 10 809-0170 Screw, #14 x ¾” Slotted Pan Head

* 210-0681 Probe Guard

* 220-0927 Air/Heat Shield, 31”

* 220-0928 Air/Heat Shield, 15 ½”

* Not illustrated.

2-25

2.14 Gas Valves and Burners

2.14.1 PMJ45 Gas Valves and Burners

NOTE: Red dot indicates propane/ butane pilot assembly; green dot indicates manufactured gas; no dot indicates natural gas.

NOTE: This style of burner heat shield

Gas Valve Conversion Kits:

Non-CE Natural to Propane: 826-1143

Non-CE Propane to Natural: 826-1144

CE Natural to Propane: 826-1200 CE Propane to Natural: 826-1201

is only used with the burner manifold above the filter unit. All others use 823-0574. See Item 7 in the parts list on the next page.

ITEM PART # COMPONENT

1 230-1177 Metal Deﬂ ector (Target) Sides, Individual

2 230-1206 Metal Deﬂ ector (Target) Rear, Individual

Ignitors (see Section 2.14.3)

3 826-1155 Ignitor Kit, Optional Piezo

Burner Manifold

810-2710 FV 810-2708 DV, Left Side 810-2709 DV, Right Side

* 810-0691

* Not illustrated.

Tube, Vent (CE, 810-1166)

MJ45 Gas Valves and Burners continued on next page

2-26

ITEM PART # COMPONENT

Oriﬁ ces (for high altitude and special gasses, contact Frymaster)

826-1357 1.45 mm, Natural Gas (pkg. of 10) 826-1387 .86 mm, Propane/Butane Gas (pkg. of 10) 810-0407 2.15 mm, Manufactured Gas 812-1203 1.00 mm, Butane Gas

Pilot Assemblies, Non-CE

810-1873 Natural Gas with Thermopile (Twin Push-on Terminals) 807-3485 Natural Gas with Thermopile (Twin Spade Terminals)

106-1909SP Pro./But. Gas with Thermopile (Twin Spade Terminals)

Pilot Assemblies, CE and Export

806-8688SP Natural Gas with Thermocouple (Co-axial Lead)

106-9570 Natural Gas with Thermocouple Australia (Co-axial Lead) 106-1911 Natural Gas, Australian (Co-axial Lead) 810-2071 Natural Gas, mV

806-8689SP Pro./But. Gas with Thermocouple (Co-axial Lead)

106-9571 Pro./But. Gas with Thermocouple, Australia (Co-axial Lead) 106-1912 Pro./But. Gas, Australian (Co-axial Lead) 810-2070 Pro./But. Gas, mV

823-5295 823-5296 823-0574 826-2109 826-2110 826-2111

Burner Heat Shield Assemblies

Filter Burner Position, Left (includes bracket, 210-9729) Filter Burner Position, Right (includes bracket, 210-9729) Non-Filter Burner Position (includes bracket, 930-0075) Kit, Retroﬁ t Filter Lid (includes 823-5295 and 823-5296, see Page 2-29) Kit, Retroﬁ t Filter Lid, LH Spreader (includes 823-5295, see Page 2-29) Kit, Retroﬁ t Filter Lid, RH Spreader (includes 823-5295, see Page 2-29)

Thermopile/Thermocouple

810-2007 Pilot, Natural Gas, Honeywell 810-2022 Pilot, LP Gas, Honeywell 807-3485

Thermopile, Generator with Adaptor (for use with 810-2007 & 810-2022)

810-1873 Thermopile 1TT, Spade Terminals (Non-CE Pilot Assemblies) 810-3442

Thermocouple Assembly (CE)

826-1527 Kit, Thermocouple with Adapter (CE Pilot Assemblies) 810-1723 Thermocouple Adapter (CE Pilot Assemblies)

9 810-0705

812-0278

Tube, Pilot Gas (Use with all burner assemblies except Hong Kong export units.) Tube, Pilot Gas (Use with Hong Kong export units only.)

Gas Valves, Non-CE (see Note 1 below)

807-1603 mV Natural Gas 807-4137 mV Natural, Australia (Requires kit 807-1846 to use Propane) 807-1604 mV Propane Gas 807-3294 24V Natural Gas (for 240V, use 807-0025) 807-3295 24V Propane Gas (for 240V, use 807-0759) 810-0786 E. I. Natural 810-0787 E. I. Propane

806-6710 806-6711

Gas Valves, CE

24V Natural Gas (see Note 2 below) 24V Propane Gas (see Note 2 below)

806-7101 mV Natural Gas 806-7102 mV Propane Gas

Mount Assembly (Ignitor, Electrode/Flame Sensor, Mount Plate)

806-5895 Natural Gas, Right 806-5896 Natural Gas, Left 806-5897 Pro./But. Gas, Right

806-5894 Pro./But. Gas, Left * 806-4781 Capacitor * 810-1183 Tee, ¼” Brass Compression * 826-2554 Millivolt Switch

NOTES: 1. A gas valve capacitor (P/N 806-4781) is required on gas valves used on units with thermostat controllers. 2. An adapter kit (P/N 812- 1256SP) is required to connect the high-limit thermostat to Item 11. It is included with Item 6 on Page 2-40.

2-27

2.14.2 PMJ35 Gas Valves and Burners

NOTE: This style of burner heat shield is only used with the burner manifold above the filter unit. All others use 823-0574. See Item 7 in the parts list on the next page.

NOTE: Red dot indicates propane/ butane pilot assembly; green dot indicates manufactured gas; no dot indicates natural gas.

Gas Valve Conversion Kits:

(with Honeywell Pilots)

Non-CE Natural to Propane: 826-1964 Non-CE Propane to Natural: 826-1965

2-28

ITEM PART # COMPONENT

1 230-1178 Metal Target Sides, Individual 2 230-1180 Metal Target Rear, Individual

Ignitor (see Section 2.14.3)

3 826-1155 Ignitor Kit, Optional Piezo

810-1001 Trigger/Ignitor

807-1906 Electrode Assembly 4 810-1862 5

826-1353 1.7 mm, Natural Gas (pkg. of 10)

826-1354 1.05 mm, Propane/Butane Gas (pkg. of 10)

810-0407 2.15 mm, Manufactured Gas

812-1203 1.00 mm, Butane Gas 6

810-1830 Natural Gas with Thermopile (Twin Push-on Terminals, 45) (Pro- 810-7773)

6A 106-1908SP Natural Gas with Thermopile (Twin Spade Terminals, 35) 6B 106-1909SP Pro./But. Gas with Thermopile (Twin Spade Terminals, 35)

810-0426 Natural Gas - Pilot Only (MJ45)

810-0427 Pro./But Gas - Pilot Only (MJ45)

806-8688SP Natural Gas with Thermocouple (Co-axial Lead)

106-9570 Natural Gas with Thermocouple Australia (Co-axial Lead)

106-1911 Natural Gas, Australian (Co-axial Lead)

810-2071 Natural Gas, mV

806-8689SP Pro./But. Gas with Thermocouple (Co-axial Lead)

106-9571 Pro./But. Gas with Thermocouple, Australia (Co-axial Lead)

106-1912 Pro./But. Gas, Australian (Co-axial Lead)

810-2070 Pro./But. Gas, mV

7 823-5295

823-5296

823-0574

826-2109

826-2110

826-2111

810-2007 Pilot, Natural Gas

810-2022 Pilot, LP Gas

807-3485

810-1873 Thermopile 1TT (Non-CE Pilot Assemblies, push on terminals) PMJ45 9 810-0705

812-0278

807-1603 mV Natural Gas

807-4137 mV Natural Gas (Australia) also requires kit 807-1846

807-1604 mV Propane Gas

807-3294 24V Natural Gas (for 240V, use 807-0025)

807-3295 24V Propane Gas (for 240V, use 807-0759)

810-0786 E. I. Natural

810-0787 E. I. Propane * 810-0691 Tube, Vent

NOTE: A gas valve capacitor (P/N 806-4781) is required on gas valves used on units with thermostat controllers.

Burner Manifold, Full-vat (full assembly including targets, 106-5075SP)

Oriﬁ ces (for high altitude and special gasses contact Frymaster)

Pilot Assemblies, Non-CE

Pilot Assemblies, CE and Export

Burner Heat Shield Assemblies

Filter Burner Position, Left (includes bracket, 210-9729) Filter Burner Position, Right (includes bracket, 210-9729) Non-ﬁ lter Burner Position (includes bracket, 930-0075) Kit, Retroﬁ t Filter Lid (includes 823-5295 and 823-5296, see Page 2-29) Kit, Retroﬁ t Filter Lid, LH Spreader (includes 823-5295, see Page 2-29) Kit, Retroﬁ t Filter Lid, RH Spreader (includes 823-5295, see Page 2-29)

Thermopile/Thermocouple

Thermopile, Generator with Adaptor (for use with 810-2007, 810-2022) PMJ35

Tube, Pilot Gas (Use with all burner assemblies except Hong Kong export units.) Tube, Pilot Gas (Use with Hong Kong export units only.)

Gas Valves, Non-CE (see note below)

2-29

2.14.3 Ignitors

LEFT

806-5895 - Natural

806-5897 - Propane

806-5896 - Propane

ITEM PART # COMPONENT

1 807-1928 Flame Sensor Electrode 2 910-2077 Pilot Mount 3 809-0121 Screw, 10-32 x ½” Hex Head 4 809-0500 Screw, Stainless Steel #10 x ½” Hex Head Washer 5 Plate, Pilot

910-2078 Left

910-2079 Right 6 910-2080 Heat Shield 7 Ignitor

807-1707 Natural

807-1708 Propane

* Not illustrated.

RIGHT

806-5894 - Natural

2-30

2.15 Oil Return Components

Oil Return Handle Full-Vat Assembly

(106-4002)

115V Pump/Motor Assembly shown.

Dual-Vat

(106-4003)

Filter Suction Manifold

Filter Return Manifold

2-31

ITEM PART # COMPONENT

106-4002SP FV Oil Return Assembly, MJ45 106-4003SP DV Oil Return Assembly, MJ45 106-9265SP FV Oil Return Assembly, MJ 35

826-1712

826-1756

826-1270

826-1755 3 826-1264 Pump, Viking 4 GPM 2-piece

106-3987 4 813-0251 Nipple, ½” x 3.5 BM 5 823-4739 Bracket, Suction Nipple

106-3986 6 813-0247 Nipple, ½” x 3.5 BM 7 823-4737 Bracket, Suction Nipple 8 810-1668 Adapter, Male * 810-1339 Flexline, 4.5”

9 810-1669 Adapter, Female

10 810-1680 Flexline, 6.5” 11 810-1160 Flexline, ⅝” x 3” 12 813-0062 Elbow, ½” 90° BM 13 813-0165 Elbow, Street ½” NPT BM

14 807-2104 15 200-9065

* 220-4357

16 816-0644

* 811-0746 * 811-0861 * 807-1472 * 807-1473

* 806-8065 100V, 25W, 18” * 806-5933 120V, 25W, 18” * 806-9245 120V, 25W, 36” * 806-6731 120V, 40W, 56” * 806-5934 208/240V, 25W, 18” * 106-5768 250V, 25W, 18” * 106-5849 250V, 45W, 36” * 806-6733 250V, 70W, 56” * 106-5011 Extension Harness * 826-2100 Kit, Retroﬁ t 120V Heater

17 823-4743 Connector, Female Suction

* 813-0156 Pipe Plug, ½” * 810-1003 Valve, 180° 3-way Ball * 807-2484 Valve, Solenoid Vent * 811-0932 Tubing, Teﬂ on

18 813-0275 Nipple, ½” x 9 NPT BM Pipe 19 813-0087 Nipple, ½” x 1.5 NPT BM Pipe 20 813-0460 Nipple, ½” x 3 NPT BM Pipe

* Not illustrated.

Handle Assemblies, Oil Return Valve

Pump and Motor

100-120V, 60 Hz (motor and gasket) 208V, 50/60 Hz (motor and gasket) 230V, 50/60 Hz (motor and gasket) 250V, 50/60 Hz (motor and gasket)

Filter Return Manifold (see additional components below)

Filter Suction Manifold (see additional components below)

Included with Filter Return/Suction Manifolds

Oil Return Handle

Microswitch (included with Item 1) Handle (included with Item 1, MJ45) Handle (included with Item 1, MJ35) Grip (included with Item 1)

Miscellaneous

Aluminum Tape (150’ roll) Foam Tape (sold by the foot) Heater Strip 120V-40W 56” (for 120V fryers) Heater Strip 240V-70W 56” (for 208-240V fryers)

Heater Tape

Oil Return Components continued on next page . . .

2-32

ITEM PART # COMPONENT

21 816-0093 Gasket, Pump and Motor 22 816-0220 23 900-2110 24 806-8342 25

806-9385 Full-vat

900-2112 Dual-vat

26 826-1376 Nut, 10-32 Keps Hex (pkg. of 10) 27 826-1366 Nut, 4-40 Keps Hex with External Tooth (pkg. of 25) 28 809-0194 Washer, Flat 29 809-0056 Nut, 5/16”-18 Hex 30 809-0514 Capscrew, 5/16”-18NC Hex SAE

* WIR0220 Pump Wiring Assembly

31 826-1359 Screw, 4-40 x ¾” Keps Hex (pkg. of 25)

* Kit, Heater Tape Retroﬁ t

826-2118 Kit, 100 VAC

826-2119 Kit, 120 VAC

826-2120 Kit, 220/240 VAC

826-2121 Kit, 250 VAC

* Not illustrated.

Insulation, Drain Safety Box (included with Item 1) Cover, Oil Return Microswitch (included with Item 1) Support, Oil Return Valve (included with Item 1)

Support, Microswitch Mount (included with Item 1)

/16” SAE

2.16 Oil Return Assembly

ITEM PART # COMPONENT

1 106-4002 Valve Assembly, Full-vat 2 106-4003 Valve Assembly, Dual-vat 3 807-2484 Valve, Solenoid, ¼” NPT 4 810-1003 180° 3-way Valve 5 810-1372 Fitting, 90° ¼” NPT, ⅜” Tube 6 810-1668 Adaptor, Male, ⅝” OD x ½” 7 810-1669 Adaptor, Female, ⅞” OD x ½” 8 810-1680 Flexline, ⅝” OD x 6.5” Long 9 810-2791 Manifold, Oil Return

10 813-0156 Plug, ½”, Hex Head BM 11 813-0165 Elbow, Street, ½” x ½” NPT, 90° BM 12 813-0469 Cap, Pipe, ½” BM 13 816-0644 Grip, Yellow

* Not illustrated.

2-33

2.17 Thermostats and Timers

ITEM PART # COMPONENT

Operating Thermostat Assembly, Fenwall

1 806-0183 With Two Blue Insulated Push-on Terminals, 4” (MJ35 & 45, Non-CE) 2

* * 106-7036 With One Wire Push-on, One Fork Terminal, 4” (MJ45, CE) 3 806-9617 With One Blue Insulated Push-on, One Fork Terminal, 4” 4 806-0087SP Thermostat Dial Plate Assembly

5 826-1177 425°F High-limit (Non-CE) 6 806-7550 218°C High-limit (CE; includes adapter for gas valve hookup. See note on

* 810-0999 Flex Shaft, Control Panel Mount Assembly, 9 ¼” overall 7 810-0345 Shaft, 7.25” Thermostat Flexible Extension 8 810-1651 Shaft, 5.50” Thermostat Flexible Extension * 810-0276 Shaft, 2.25” Thermostat Flexible Extension 9 900-2071 Mounting Bracket

10 826-2698 15-minute Electronic Timer, Single

* 826-2699 15-minute Electronic Timer, Multi-vat System

11 810-0585 15-minute Mechanical Timer 12 910-1551 15-minute Mechanical Timer Bezel

13 810-0387 Knob, Control, Solid State Controller 14 826-1395 Plug Button (pkg. of 10) 15 810-1287 Knob, 15-minute Mechanical Timer 16 810-0110 Knob, Fenwal Thermostat with Two Allenhead Screws 17 810-0334 Knob, with Skirt

* 810-0388 Knob, 1” Black * 826-1575 Kit, Retroﬁ t 5-minute Timer

18 807-4134

* 106-4386SP Toggle Switch, Optional * 806-4206 Temperature Probe * 210-0681 Probe Guard

* Not illustrated.

806-5816 806-7972

With One Wire Push-on, One Fork Terminal, 3” (MJ35, Non-CE) With One Wire Push-on, One Fork Terminal, 3” (MJ35, CE)

(MJ35 & 45, CE)

High-Limit Thermostat

Page 2-34.)

Flex Shaft

Timers, Basket Lift

Knobs

Butterﬂ y/Envelope Adapter (CE; included in 810-3442)

2-34

2.18 Wiring Harnesses, Pin Terminals, and Power Cords

14 15

9 10

ITEM PART # COMPONENT

Connectors

1 807-1068 2-pin Female 2 807-0158 6-pin Female 3 807-0156 9-pin Female 4 807-0159 12-pin Female 5 807-0875 15-pin Female 6 807-1067 2-pin Male 7 807-0157 6-pin Male 8 807-0155 9-pin Male 9 807-0160 12-pin Male

10 807-0804 15-pin Male 11 826-1332 Terminal, Female Split Pin (pkg. of 25) 12 826-1333 Terminal, Male Split Pin (pkg. of 25) 13 807-2518 Plug, Mate-N-Lock (Dummy Pin) 14 826-1331 Terminal, M&L Female Split Pin (pkg. of 25) 15 826-1336 Terminal, M&L Male Split Pin (pkg. of 25)

* 807-0154 Cord Set (Power Cord)

* Not illustrated.

2-35

2.19 Garland Range (S35) Parts

ITEM PART # COMPONENT

Cabinetry

* 806-6741 Cabinet Assembly, H35 * 900-2266 Cabinet, Back/Upper * 823-2282 Fluecap * 824-0517 Topcap * 806-6765 Door Assembly * 806-3943SP Frypot Assembly * 106-4430 Flue Assembly * 810-1195 Top Back Guard * 806-6985 Wiring Harness * 810-1306 1/2” Brass Manual Gas Valve * KIT1653 Garland Piezo Ignitor Kit

* Not illustrated.

2.20 Power Shower

ITEM PART # COMPONENT

Power Shower Assembly

806-4542SP MJ35 806-4503SP MJ45

Components

1 823-1522 Power Shower Body, MJ35 2 823-1485 Power Shower Body, MJ45 3 809-0415 Screw, Clean-out 4 826-1344 O-ring 5 826-1390 Seal 6 814-0001 Grip

2-36

Frymaster, L.L.C., 8700 Line Avenue, Shreveport, Louisiana 71106

TEL 1-318-865-1711 FAX (Parts) 1-318-219-7140 FAX (Tech Support) 1-318-219-7135

PRINTED IN THE UNITED STATES

SERVICE HOTLINE

1-800-551-8633

819-6092

March 2011

Frymaster PERFORMANCE PRO 45, PERFORMANCE PRO 35 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual