Frymaster PERFORMANCE PRO 45, PERFORMANCE PRO 35 User Manual

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.

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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.

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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.

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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.

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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.

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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

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