Pitco Frialator TURBOFRY2000 Service Manual
Service Manual
for the
Pitco Frialator
Literature # L20-155 Rev 0 Patent Pending Manufactured in
Printed 9 May 1997 The United States of America
FOR YOUR SAFETY :
Do not store gasoline or other flammable vapors
or liquids in the vicinity of this or any other appliance.
TO THE PURCHASER
POST IN A PROMINENT LOCATION INSTRUCTIONS TO BE FOLLOWED IN THE
EVENT THAT AN OPERATOR SMELLS
GAS. OBT AIN THIS INFORMATION FROM
YOUR LOCAL GAS SUPPLIER.
WARNING:
IMPROPER INSTALLATION, ADJUSTMENT , AL TERA TION, SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATING AND MAINTENANCE MANUALS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS
EQUIPMENT.
WARNING
DO NOT use an open flame to check for gas leaks!
Keep all open flames away from the machine at all
times.
WARNING
Ensure that the machine can get enough air to keep
the flame burning correctly . If the flame is starved
of air it can give off a dangerous carbon monoxide
gas. Carbon Monoxide is a clear odorless gas that
can cause suffocation.
WARNING
Blocking the flue will also cause the unit to overheat. DO NOT obstruct the flow of combustion/
ventilation or air opening around the machine. Ensure that you meet the minimum clearances specified in the installation instructions. Adequate clear ance around the unit is necessary for servicing and
proper burner operation.
WARNING
The power supply must be disconnected before servicing or cleaning the unit.
WARNING
DO NOT supply the fryer with a gas that is not
identified on the data plate, located on the inside of
one of the doors of the machine. If you need to
convert the machine to another type of fuel, contact your dealer or Authorized Blodgett Service
Agency.
WARNING
Machines equipped with casters and a flexible
power cord, must be connected to a gas supply with
a Quick-Disconnect device. This quick disconnect
must comply with ANSI Z24.41. T o limit the movement of the unit without depending on the connector or quick disconnect, a restraining cable must
also be installed.
WARNING
Use only a B/C or A/B/C extinguisher that contains the dry chemical Sodium Bicarbonate or
Potasium Bicarbonate should be used to extinguish
any fires.
WARNING
When the fryer is in its operating location, lock the
casters and reattach the restraining device to the
rear of the machine.
WARNING
Shortening, when it is at cooking temperatures, is
very HOT and DANGEROUS! Use extreme caution when handling! Use the proper protective gear
such as insulated gloves, aprons, face shield and
sleeves when handling hot shortening. DO NOT
attempt to move any machine that has hot oil in it.
Allow the oil to cool to room temperature or drain
the oil into a suitable container before moving the
fryer.
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ORIGINAL EQUIPMENT LIMITED WARRANTY - TURBOFRY 2000
General Warranty
Pitco Frialator, Inc. warrants to the original user of its T urbofry 2000 cooking appliance that said appliance and related equipment will be free from
defects in material and workmanship under normal use for a period of one (1) year from the date of installation, with appropriate documentation, subject
to the following additions, exceptions, exclusions and limitations.
What is covered
This warranty is limited to the repair or replacement at the Company’s option, without charge, of any part found to be defective within the warranty
period and reasonable expenses incurred for freight and material for the installation of such part; in addition, the Company’s obligation shall be limited to
reimbursement for normal labor on such parts.
Pitco Frialator, Inc. agrees to pay the G.S. Blodgett Corporation Authorized Service and Parts Distributor, for any labor and material required to
repair or replace, at the Company’s option, any part which may fail due to defects in material or workmanship during the above general warranty period.
Fry T anks
In addition, the Company warrants to the original user of any fry tank to be free from defects for a period of ten (10) years from the date of
manufacture. Labor and freight shall be the responsibility of the user. This shall only obligate the Company to repair or replace, at its option, any fry tank
which it determines to be defective. Claims under this item shall be supported by a statement detailing the defect, and the Company may require the return
of the fry tank claimed to be defective.
Computer or Digital Cooking Controller
In addition, the Company warrants to the original user of any Cooking Computer or Digital Controller to be free from defects for a period of two (2)
years,from the date of manufacture. During the two (2) year period all charges involved in the replacement of a Pitco Computer or Digital Controller will
be the responsibility of Pitco Frialator Inc.
How to Keep Your Warranty in For ce
€ Make sure any shipping damages are reported immediately. Damages of this nature are the responsibility of the carrier.
€ Install the unit properly. This is the responsibility of the installer and the procedures are outlined in the manual. Do not install it in a home
or residence.
€ Maintain the unit properly. This is the responsibility of the user, the procedures are outlined in the manual.
What is NOT covered under this Warranty
€ Adjustments, such as calibration, leveling, tightening of fasteners or plumbing or electrical connections normally associated with initial
installation are not covered under this warranty. These procedures are outlined in the installation manual.
€ Damaged due to flood, fire or other acts of Nature are not covered under this warranty.
€ If the unit is used for a purpose other than for which it was intended or designed, resulting damages are not covered under the warranty .
€ Failures due to erratic voltage or gas supplies are not covered under the warranty.
€ Material alterations or modifications from the condition in which the unit left the factory are not covered under the warranty.
€ Units with unreadable, obliterated or removed serial number rating plates are not covered by the warranty.
€ Any parts other than Genuine OEM parts from Pitco Frialator, Inc. or its Authorized Parts and Service Distributors are not covered by the
warranty.
€ Any other failure which is not attributable to a defect in materials or workmanship is not covered bt the warranty.
This warranty specifically excludes parts which wear or would be replaced under normal usage, including, but not limited to, electric lamps, fuses,
interior or exterior finishes and gaskets.
Limits to the Warranty
Outside the United States of America and Canada, this warranty is limited to the replacement of parts and Pitco Frialator , Inc. will not bear any other
expense be it labor, mileage, freight or travel.
Charges for mileage over one hundred (100) miles, travel time over two (2) hours, overtime, and holiday charges are not covered under this warranty .
These charges are the responsibility of the individual or firm requesting these services.
If any oral statements have been made regarding the appliance, these statements do not constitute warranties and are not part of the contract of sale.
This limited warranty constitutes the complete, final and exclusive statement with regard to warranties.
THIS LIMITED WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES WHETHER WRITTEN, ORAL OR IM-
PLIED, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANT ABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR
W ARRANTY AGAINST LATENT DEFECTS.
Limitations of Liability
In the event of a warranty or other claim, the sole obligation of Pitco Frialator, Inc. will be the repair or replacement, at the Company’ s option, of the
appliance or the component part. This repair or replacement will be at the expense of Pitco Frialator, Inc. except as limited by this warranty statement. Any
repair or replacement under this warranty does not constitute an extension in time to the original warranty. Parts covered under this warranty will be
repaired or replaced, at the Company’s option, with new or functionally operative parts. The liability of Pitco Frialator, Inc. on any claim of any kind,
including claims based on warranty, express or implied contract, negligence, strict liability or any other legal theories will be exclusively the repair or
replacement of the appliance. This liability will not include, and the purchaser specifically renounces any right to recover special, incidental, consequential or other damages of any kind, including, but not limited to, injuries to persons, damage to property, loss of profits or anticipated loss of the use of this
appliance.
If any provision of this warranty is unenforceable under the law of any jurisdiction, that provision only will be inapplicable there, and the remainder
of the warranty will remain unaffected. The maximum exclusion or limitation allowed by law will be substituted for the unenforceable provision.
How to Obtain W arranty Service
First direct your claim to the G.S. Blodgett Corporation Authorized Service and Parts Distributor closest to you giving complete model, serial and
code numbers, voltage, gas type, and description of the problem. Proof of the date of installation and/or the sales slip may also be required. If this
procedure fails to be satisfactory, write the National Service Manager , Pitco Frialator, Inc., P. O. Box 501, Concord, NH. 03302-0501. USA
This warranty gives you certain specific legal rights; you may have other rights which vary from state to state.
ii
Table of Contents
ORIGINAL EQUIPMENT LIMITED WARRANTY ................................ ii
TABLE OF CONTENTS ......................................................................... iii
SPECIFICATIONS and DATA ................................................................. iv
INTRODUCTION ..................................................................................... 1
How does it work? ................................................................................ 1
230 VAC, High Voltage System ............................................................ 1
24 VAC, Low Voltage System............................................................... 2
Component Recognition - Fry T ank...................................................... 5
Component Recognition - Controls...................................................... 6
PREVENTATIVE MAINTENANCE ....................................................... 7
Daily Cleaning ...................................................................................... 7
W eekly Cleaning................................................................................... 7
Vacuum Gauge Inspection .................................................................... 7
Boil Out Procedure ............................................................................... 7
Air Filter Inspection .............................................................................. 9
Inspect O-Rings .................................................................................. 10
Service T echnician Inspection ............................................................. 10
TROUBLESHOOTING........................................................................... 11
COMPONENT TROUBLESHOOTING ................................................ 12
T emperature Probe .............................................................................. 12
Relays ................................................................................................. 12
Hi Limits ............................................................................................. 12
Drain Valve & Return Valve Switches................................................. 12
Transformer......................................................................................... 12
Blower ................................................................................................ 13
Pressure Switch ................................................................................... 13
Ignition Control Modules .................................................................... 13
Ignitors ................................................................................................ 13
PARTS ...................................................................................................... 15
General................................................................................................ 15
Entrance Box Assembly............................................................... 16 - 17
SCHEMATICS..................................................................................18 - 20
700268 Rev C - Page 1, Left Side of schematic.................................. 18
700268 Rev C - Page 1, Right Side of schematic ............................... 19
700268 Rev C - Page 2 ....................................................................... 20
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SPECIFCA TIONS and DAT A
Gas Consumption................................................................................................ 240 kbtu/hr
Efficiency ..................................................................................................................71-73%
Cooking capacity , fries ............................................................................................ 260 lb/hr
Supply V oltage .............................................................................................. 208 - 230 VAC
Control V oltage ........................................................................................................ 24 VAC
Heat up time - Liquid ................................................................................................20 mins
Heat up time - Solid ..................................................................................................25 mins
Minimum melt time - Solid only................................................................................10 mins
Sump Thermostat temp ..................................................................................Open at 135°F
Close at 105°F
Spark Gap ........................................................................... 0.1 ± 0.005" (2.54 ± 0.127mm)
Hi Limit specs .................................................................................................... 435 - 465°F
Burner flame color .........................................................................................Yellowish blue
Blower speed ....................................................................................... Set by Speed control
Ignition lockout time ..................................................................................................15 secs
Pressure switch.................................................................... Open below 0.8" WC (0.2 kPa)
Close above 0.1" WC (0.325 kPa)
Blower Air High Fire Pressure ...............................................................Nat - 5.5 - 5.6" WC
LP - 4.8 - 4.9" WC
Blower Air Low Fire Pressure ....................................................................... Nat - 0.4" WC
LP - 0.4" WC
Gas Pressure at Tap in High Fire Gas Line ....................................................... Nat - 4" WC
LP - 3.5" WC
Heat Time from 250°F to 300°F.................................................................. 2:25 - 3 Minutes
Pump Rate, clean oil, Full Pan to Fry T ank................................... 5 - 5:45 Minutes/Seconds
Pump Rate, clean oil, to empty Circulating System............................................. 45 Seconds
(This is done after the T ank has been cleaned, drained and the filters removed)
Low Fire Orifice Size................................................................... Nat & LP - #54 Drill Size
Hi Fire Orifice Size ........................................................................................... Nat - 0.328"
LP - 0.302"
Air Bleed T ip Orifice ............................................................................. Nat - #52 Drill Size
LP - #45 Drill Size
Air collar Size ..................................................................................................... Nat - 1.06"
LP - 1.165"
Minimum Gas Pressure Requirments ................................................... Nat & LP - 5.0" WC
Maximum Gas Pressure Requirements.................................................. Nat & LP - 14" WC
iv
v
INTRODUCTION
How does it work?
The development of the TURBOFRY 2000 fills the
needs of the food industry that have been, until now ,
unattainable. They are:
1. Continuous filtration of the food oil.
2. Crispier than ever fried food coatings due to convection currents.
3. High production from a high efficiency heat transfer system.
Continuous filtration of the cooking oil provides clean,
clear oil, even through busy periods. This means
breaded particles do not settle on heating surfaces and
burn, which in turn means longer oil life and lower
oil costs. The clean oil produces foods with coatings
free of burnt food particles that look and taste more
appetizing. Turbofry 2000 has an advanced filter system that makes clean up quick and easy. The main
filters trap the larger crumbs and can be lifted out for
easy cleaning and replacement.
The Turbofry 2000 uses a heating process, within the
cooking area, known as "Convection", foods cook
with crisper coatings because hot oil is forced between
the individual pieces of food, the breading or outer
coating gets seared quickly before the food can absorb as much oil as with a standard fryer. This will
produce a finished product that is much lower in absorbed oils.
There are two parts to the control system in the Tur bofry 2000 fryer, the 230 VAC or high voltage circuit and the 24 VAC or low voltage circuit.
230 VAC, High Voltage System:
230 VAC is applied to the machine -
• The Pump Motor Relay switch contact are supplied with 230 VAC.
• The Sump Heat System is supplied with 230
V AC. When the Sump T emperature Switch closes
the Sump Heat Tape will start to heat.
• The Motor Relay switch contacts will be supplied with 230 VAC. This relay will be explained
later in this manual.
• On machines equipped with the Solid Shortening Option the switch contacts of the Heat Tape
Relay will also be supplied with 230 VAC. This
relay is controlled by the Pipe Temperature
Switch.
• The primary coils of the Transformer will be supplied with 230 VAC. At this point the 24 VAC,
low voltage circuit will become energized.
The Turbofry 2000 has a high efficiency gas combustion system that transfers heat more efficiently than
regular fryers. The high input rate in conjunction with
a large heat transfer surface area give this fryer the
ability to cook high capacity loads effortlessly .
When installing the Turbofry 2000 follow the instructions in the Installation and Operating Manual.
1
24 VAC, Low Voltage System:
Digital Control Condition - Power supply ON Digital Control OFF.
• 24 VAC is supplied to the Digital Temperature Controller.
• The Drain Valve Switch is supplied with 24 VAC. If the Drain Valve is closed the switch will allow 24
VAC to be supplied to the Drain Interlock connection at the Controller .
• The Power Relay switch contacts will also be supplied with 24 VAC.
2
Condition - Digital control is switched ON but there is NO demand for heat:
• 24 VAC is supplied to the On Relay (K7) relay which energizes and supplies 24 VAC to the coil of the
Power Relay (K1).
• The Power Relay (K1) energizes and supplies 24 VAC to following places:
→ Hi Limit Switch (S2) - If the Hi limit (S2) is closed 24 VAC is supplied to the Pressure Switch (PS1),
the Pressure Switch (PS1) will close and supply 24 VAC to the Gas Valve (V1) when the Blower
(M2) comes up to speed.
→ Melt Relay (K2) - if the Digital Control (A1) is in Melt Cycle the Melt Relay (K2) is energized and
the circuit will be open. If the Digital Control (A1) has completed the Melt Cycle the Melt Relay (K2)
will be de-energized and the Pump Override Switch (S1) will be supplied with 24 VAC.
→ Blower Speed Control (VR1) - the Blower Speed Control (VR1) will cause the Blower (M2) to run
in Low Fire mode until it receives a signal from the Check Fryer Relay (K5) to tell it to run in the
High Fire mode.
→ Pipe T emperature Switch (TS1) - When the temperature in the filter piping falls below a certain level
the Pipe Temperature Switch (TS1) will close and supply 24 VAC to the Heater Relay (K6). In this
state the Heat Tape (HR2-HR6) will be supplied with 230 VAC and will continue to heat until the
Pipe T emperature Switch Opens at its designed temperature.
Condition - Demand for heat (All Controls):
• 24 VAC is supplied to the switch points of the Check Fryer Relay (K5). Since the Check Fryer Relay is
energized by the Ignition Control Module when it runs in High Fire Mode it will remain de-energized and
the Check Fryer Light (DS1) will be illuminated.
• 24 VAC is supplied to the Ignition control Module at terminal #6. The Ignition Control Module will cause
a spark at the Ignitor (PR1) and supply the Gas Valve (V2) with 24 VAC. At this time the Low Fire flame
will ignite. The Ignition Control Module will seek a flame sense signal from the Ignitor (PR1). The
Ignition Control Module will then supply 24 VAC to the Gas Valve (V3) and the High Fire Flame will
run. (Under normal working conditions it should take 2.6 - 4 seconds for the High Fire Flame to light.)
The same 24 VAC signal supplied to the Gas Valve (V3) is also supplied to the Check Fryer Relay (K5).
When the Check Fryer Relay energizes it will stop supplying 24 VAC to the Check Fryer Light and start
supplying 24 VAC to the Blower Speed Control. The Blower speed will then increase to High Fire speed
which will sustain the air demand for High Fire.
Condition - Auto Pump start (All Contr ols):
• The Pump Relay (K4) is supplied with 24 VAC from the Heater Relay (K6) and, if all of the following
conditions are met, the Circulation Pump (M1) will begin to run:
• When the Controller is turned off the Power Relay (K1) is de-energized which supplies 24 VAC to one
side of the Pump Override switch (S1). If the pump is NOT running the Pump Override Switch (S1) will
be in the open condition. In the open position the Pump Override Switch will be in the correct position for
Automatic Pump Start. When the Control is first turned on it will send a 24 VDC signal to the coil of the
Melt Relay (K2). This will energize the relay and open the circuit to the Pump Override Switch. When
the Control has exited the Melt Cycle or run past the Minimum Melt Time it will stop supplying the Melt
Relay (K2) with 24 VDC and the Pump Override Switch will be supplied with 24 VAC At this time,
assuming the Sump T emperature is above 135°F (57°C) and the Heater Relay is de-energized the Pump
Relay (K4) will be supplied with 24 VAC and the Circulation Pump will be supplied with 230 VAC.
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