Frymaster YFG255 User Manual
YFG255 Rethermalizer
Service & Parts Manual
Frymaster, a member of the Commercial Food Equipment Service Association, recommends
using CFESA Certified Technicians.
24-Hour Service Hotline
1-800-551-8633
www.frymaster.com
Email: service@frymaster.com
*8196900*
05/2016
Please read all sections of this manual and retain for future reference.
This product has been certified as commercial cooking equipment and MUST be installed by
professional personnel as specified. Installation, maintenance and repairs should be performed
by your Frymaster Factory Authorized Servicer (FAS).
DANGER
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any
other cooking appliance.
DANGER
Instructions explaining procedures to be followed MUST be posted in a prominent location in
the event the operator detects a gas leak. This information can be obtained from the local gas
company or gas supplier.
DANGER
Safe and satisfactory operation of your equipment depends on proper installation. Installation
MUST conform with local codes, or in absence of local codes, with the National Fuel Gas Code,
ANSI Z223.1; The Natural Gas Installation Code, CAN/CGA-B149.1; The Propane Installation
Code, CAN/CGA-B149.2; or The latest edition of the National Electric Code, N.F.P.A. 70.
NOTICE
If, during the warranty period, the customer uses a part for this Manitowoc Food Service
equipment other than an unmodified new or recycled part purchased directly from Frymaster or
any of its authorized servicers, and/or the part being used is modified from its original
configuration, this warranty will be void. Further, Frymaster 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 servicer.
DANGER
The front ledge of the rethermalizer is not a step. Do not stand on the rethermalizer. Serious
injury can result from slips or contact with the hot water.
WARNING
Drawings and photos used in this manual are intended to illustrate operational, cleaning and
technical procedures and may not conform to on-site management operational procedures.
WARNING
No structural material on the rethermalizer should be altered or removed to accommodate
placement of the rethermalizer under a hood. Questions? Call the Frymaster Service Hotline at
1-800-551-8633.
NOTICE
This equipment is to be installed in compliance with the basic plumbing code of The Building
Officials and Code Administrators International, Inc. (BOCA) and the Food Service Sanitation
Manual of the Food and Drug Administration.
NOTICE
The Commonwealth of Massachusetts requires any and all gas products to be installed by a
licensed plumber or pipe fitter.
CONTROLLERS
FCC
This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions:
1) This device may not cause harmful interference, and 2) This device must accept any interference
received, including interference that may cause undesired operation. While this device is a verified Class
A device, it has been shown to meet the Class B limits.
CANADA
This digital apparatus does not exceed the Class A or B limits for radio noise emissions as set out by the
ICES-003 standard of the Canadian Department of Communications.
Cet appareil numerique n’emet pas de bruits radioelectriques depassany les limites de classe A et B
prescrites dans la norme NMB-003 edictee par le Ministre des Communcations du Canada.
DANGER
THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALI FORNIA TO CAUSE
CANCER AND/OR BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
Operation, installation, and servicing of this product could expose you to airborne particles of
glasswool or ceramic fibers, crystalline silica, and/or carbon monoxide. Inhalation of airborne
particles of glasswool or ceramic fibers is known to the State of California to cause cancer.
Inhalation of carbon monoxide is known to the State of California to cause birth defects or other
reproductive harm.
WARNING
Do not bang rethermalizer baskets or other utensils on the rethermalizer’s joiner strip. The strip
is present to seal the joint between the cookpot vessels. Banging rethermalizer baskets on the
strip will distort the strip, adversely affecting its fit. It is designed for a tight fit and should only
be removed for cleaning.
DANGER
Improper installation, adjustment, maintenance or service, and unauthorized alterations or
modifications can cause property damage, injury, or death. Read the installation, operating and
service instructions thoroughly before installing or servicing this equipment. Only qualified
service personnel may convert this appliance to use a gas other than that for which it was
originally configured.
DANGER
Adequate means must be provided to limit the movement of this appliance without depending
upon the gas line connection or transmitting stress to the electrical conduit. Single
rethermalizers equipped with legs must be stabilized by installing anchor straps. All
rethermalizers equipped with casters must be stabilized by installing restraining chains. If a
flexible gas line is used, an additional restraining cable must be connected at all times when the
rethermalizer is in use.
YFG255 Series Rethermalizers
Service & Parts Manual
TABLE OF CONTENTS
Page #
1. SERVICE PROCEDURES 1-1
1.1 Functional Description 1-1
1.2 Accessing Fryers for Service 1-3
1.3 Cleaning the Gas Valve Vent Tube (if applicable) 1-3
1.4 Adjusting Burner Manifold Gas Pressure 1-3
1.5 Replacing Rethermalizer Components 1-4
1.6 Troubleshooting and Problem Isolation 1-13
1.7 Troubleshooting Guides 1-18
1.8 Probe Resistance Chart 1-20
1.9 Wiring Diagram 1-21
2. PARTS LIST 2-1
2.1 YFG255 Cabinet and Related Components 2-1
2.2 Cookpot Assemblies and Components 2-3
2.3 Transformer Boxes and Control Frame Assemblies 2-4
2.4 Harnesses 2-5
2.5 Plumbing, Incoming Water 2-6
2.6 Plumbing, Drain 2-7
2.7 Plumbing, Gas Manifold 2-8
2.8 Fasteners 2-9
)
)
YFG255 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
1.1 Functional Description
YFG255 Series gas rethermalizers contain a welded stainless steel cookpot that is heated by gas
flames diffused evenly through tubes built into the cookpot.
Flames originate from orifices in a burner manifold positioned beneath the burners. The burners are
positioned in the tube openings, at the front of the cookpot. The diameter of the orifices differs for
natural (CE:G20/G25) and LP (CE:G31) gas as indicated in the accompanying table.
NON-CE (Altitudes of 2000 feet or less
MODEL
YFG255 90
INPUT
(BTU)
GAS
TYPE
NAT
LP
ORIFICE
MM
(INCH)
2.38(#42)
1.51(#53)
ORIFICE
PART NO.
810-2926
810-2941
QTY
2
2
EQUIPMENT
PRESSURE
MBAR INCH W.C.
10
27.5
4
11
CE ONLY (Altitudes of 2000 feet or less
MODEL
YFG255 26.4
INPUT
(kW)
GAS
TYPE
G20
G25
G31
ORIFICE
MM
(INCH)
2,38
2,38
1,51
ORIFICE
PART NO.
810-2926
810-2926
810-2941
QTY/
COLOR
2/BLUE
2/BLUE
2/RED
EQUIPMENT
PRESSURE
MBAR INCH W.C.
10,0
15,0
27,0
4,0
6,0
10,8
An electromechanical gas valve regulates gas flow to the manifold. YFG255 Series gas
rethermalizers are equipped with a 24-volt valve system with an electronic ignition system.
Electronic Ignition Configuration
An ignition module connected to an ignitor assembly controls ignition. The ignition module
performs three important functions: it provides an ignition spark, supplies voltage to the gas valve,
and proofs the pilot flame.
The module contains a 60-second time delay circuit and a coil that activates the gas valve. The
ignitor assembly consists of a spark plug, a pilot, and a flame 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. Current is supplied to the other leg of the heat relay coil which then 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 float
switch. Simultaneously, the module causes the ignitor to spark for up to 60 seconds to light the pilot
flame. A flame sensor verifies that the pilot is lit by measuring the flow of microamps through the
flame. If the pilot does not light (or is extinguished), current to the ignition module is interrupted,
preventing the main valve from opening, and the ignition module "locks out" until the power switch
is turned "OFF", then back "ON".
1-1
YFG255 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
A temperature probe monitors the temperature in the cookpot. When the programmed setpoint
temperature is reached, resistance in the probe causes the heat cycle circuitry in the controller to
interrupt current flow through the heat relay. This in turn interrupts the 24 VAC current to the
ignition module, resulting in closure of the gas valve.
Control Options
YFG255 Series gas rethermalizers are equipped with a factory preset temperature controller. These
are unique in that the components are wired directly to the controller and do not require an interface
board.
Temperature Probe
YFG255 rethermalizers are equipped with a temperature probe with resistance values that
correspond directly with the temperature. That is, as the temperature rises, so does resistance. See
the resistance table on page 1-20. Circuitry in the controller monitors the probe resistance and
controls burner firing when the resistance exceeds or falls below programmed temperatures
(setpoints).
1-2
YFG255 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
1.2 Accessing Rethermalizers for Servicing
DANGER
Moving a rethermalizer filled with water may cause spilling or splattering of the hot
liquid. Follow the draining instructions included with the rethermalizer before
attempting to relocate a rethermalizer for servicing.
1. Shut off the gas supply to the unit. Unplug the power cords. Remove any attached restraining
devices.
2. Disconnect the unit from the gas supply.
3. Relocate the rethermalizer for service accessibility.
4. After servicing is complete, reconnect the unit to the gas supply, reattach restraining devices, and
plug in the electrical cords.
1.3 Cleaning the Gas Valve Vent Tube (if applicable)
1. Set the rethermalizer power switch and the gas valve to the "OFF" position.
2. Carefully unscrew the vent tube from the gas valve. NOTE: The vent tube may be straightened
for ease in removal.
3. Pass a piece of ordinary binding wire (.052 inch diameter) through the tube to remove any
obstruction. Remove the wire and blow through the tube to ensure it is clear.
4. Reinstall tube and bend so that the opening is pointing downward.
1.4 Adjusting Burner Manifold Gas Pressure
WARNING
This task should be performed by qualified service personnel only.
1. Ensure that the gas valve knob is in the "OFF" position.
2. Remove the pressure tap plug from the gas valve (see arrows in photos on the following page for
location).
1-3
YFG255 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
1.4 Adjusting Burner Manifold Gas Pressure (cont.)
3. Insert the fitting for a gas pressure-measuring device into the pressure tap hole.
4. Place the gas valve in the "ON" position then place the rethermalizer power switch in the "ON"
position. When the burner lights and continues to burn, note gas pressure reading for correct
pressure in accordance with the table on page 1-1.
5. To adjust burner gas pressure, remove the cap from the gas valve regulator and adjust to correct
pressure.
6. Place the rethermalizer power switch and the gas valve in the "OFF" position. Remove the
pressure-measuring device fitting from the pressure tap hole and reinstall the pressure tap plug.
1.5 Replacing Rethermalizer Components
1.5.1 Replacing the Controller or Solid State
Relays
1. Disconnect the rethermalizer from the electrical supply.
2. Open the cabinet doors and unscrew the three controller
panel screws located beneath the bezel. The controller
panel will drop down and will rest on the open doors.
3. Mark the wires for reassembly and using a small
screwdriver loosen and remove the wires from the rear
of the controller. If replacing the relays disconnect the
wires and replace the faulty relay.
Remove the three bezel screws.
1-4
Mark wires for reassembly.
p
YFG255 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
1.5.1 Replacing the Controller or Solid State Relays cont.
4. Remove the controller from the bezel.
5. Reverse the procedure to install a new controller.
1.5.2 Replacing the Temperature Probe
1. Disconnect the rethermalizer from the electrical supply.
2. Drain the water from the cookpot. Allow the cookpot to cool
completely before proceeding.
3. Remove the rethermalizer door for easier access to the temperature
probe. Lift door up, disengage rod from lower door bracket, and
then remove door.
4. Gain access to probe wires in control box behind
controller using the steps in the previous section 1.5.1.
5. Disconnect the probe harness connector (see right).
Unplug connector.
6. Use a pin pusher to remove probe wires from the plug.
Remove probe wires.
Remove door for easier access
to tem
erature probe.
1-5
YFG255 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
1.5.2 Replacing the Temperature Probe (cont.)
7. Loosen and unscrew completely the compression nut, then the
pass-through nut from the cookpot. Proceed to the next step
before removing probe from cookpot.
Note: The temperature probe can be removed through the top
of the cookpot as follows: Ensure the probe wires have been
removed from the connector (step 6). Remove the harness
insulation. The probe can be pulled through the cookpot from
the top (complete step 7 in this section, prior to removing
probe).
8. Carefully remove the probe from the cookpot.
9. Reverse steps for installation of new probe.
IMPORTANT: When installing new probe, ensure probe is
positioned properly with the mounting hardware installed prior to
tightening the compression nut. Once tightened, the probe cannot
be repositioned.
Loosen and unscrew completely
the compression nut (bottom arrow)
first. Loosen the pass-through nut
(top arrow).
Remove the temperature probe.
1-6
YFG255 SERIES GAS RETHERMALIZERS
CHAPTER 1: SERVICE PROCEDURES
1.5.3 Replacing Float Switches
1. Disconnect the rethermalizer from the
electrical power supply.
2. Drain the water from the cookpot. Allow
the cookpot to cool completely before
proceeding.
3. Unplug the low float switch connector
from behind the controller (See section
1.5.1 for instructions on removing the
bezel.), or the high level float from the
The lower float switch (left), the high level float (right).
rear of the rethermalizer near the fresh
water connection.
4. Remove the clip and float from float switch shaft.
5. Remove the rethermalizer back to gain access to the
high level float compression nut. Removal of a
burner may be necessary to access the low level
float compression nut.
6. Loosen and completely unscrew the compression
nut from the cookpot.
7. Carefully pull the float switch shaft out of the
cookpot.
Remove the clip
8. Reverse the above steps for float switch installation.
1.5.4 Replacing the Gas Valve
DANGER
Drain the cookpot or remove the handle from the drain valve before proceeding
further.
1. Disconnect rethermalizer from electrical and gas supplies.
2. Disconnect the wires from the gas valve terminal block, marking each wire to facilitate
reconnections.
3. Remove the pilot gas line fitting from the gas valve.
1-7
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