Troubleshooting guide | Frymaster 45 Series Fryer User Manual

45 Series Gas Fryers
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
NOVEMBER 2003
*8195665*
NOTICE
IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART FOR THIS ENODIS
EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART PURCHASED
DIRECTLY FROM FRYMASTER/DEAN, OR ANY OF ITS AUTHORIZED SERVICE CENTERS,
AND/OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL CONFIGURATION, THIS
WARRANTY WILL BE VOID. FURTHER, FRYMASTER/DEAN AND ITS AFFILIATES WILL NOT BE
LIABLE FOR ANY CLAIMS, DAMAGES OR EXPENSES INCURRED BY THE CUSTOMER WHICH
ARISE DIRECTLY OR INDIRECTLY, IN WHOLE OR IN PART, DUE TO THE INSTALLATION OF
ANY MODIFIED PART AND/OR PART RECEIVED FROM AN UNAUTHORIZED SERVICE CENTER.
NOTICE
This appliance is intended for professional use only and is to be operated by qualified
personnel only. A Frymaster/DEAN Factory Authorized Service Center (FASC) or other qualified
professional should perform installation, maintenance, and repairs. Installation, maintenance,
or repairs by unqualified personnel may void the manufacturer’s warranty. See Chapter 1 of
this manual for definitions of qualified personnel.
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. See NATIONAL CODE
REQUIREMENTS in Chapter 2 of this manual for specifics.
NOTICE TO U.S. CUSTOMERS
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 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 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
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. 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 flexible gas line is used, an additional restraining cable must be connected at all
times when the fryer is in use.
The front ledge of the fryer is not a step!
from slips or contact with the hot oil.
DANGER
Do not stand on the fryer. Serious injury can result
DANGER
Do not store or use gasoline or other flammable liquids or vapors in the vicinity of this or any
other appliance.
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 filter system must be emptied into a fireproof 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 fit. It is designed for a tight fit and should only be
removed for cleaning.
ii
45 SERIES GAS FRYERS SERVICE AND PARTS MANUAL
TABLE OF CONTENTS
CHAPTER 1: Service Procedures
1.1
Functional Description....................................................................................................1-1
Pilot Ignition System.......................................................................................................1-1
Control Options...............................................................................................................1-1
Interface Boards ..............................................................................................................1-1
Thermostats and Temperature Probes.............................................................................1-3
1.2
Accessing Fryers for Servicing.......................................................................................1-4
1.3
Checking the Burner Manifold Gas Pressure..................................................................1-4
1.4
Adjusting the Pilot Flame ...............................................................................................1-5
1.5
Cleaning the Gas Valve Vent Tube ................................................................................1-6
1.6
Adjusting Burner Ceramic Target Spacing and Alignment ............................................1-6
1.7
Calibrating the Thermostat Control ................................................................................1-6
1.8
Replacing Fryer Components .........................................................................................1-7
1.8.1 Replacing the Controller or Computer............................................................................1-7
1.8.2 Replacing the Operating Thermostat ..............................................................................1-8
1.8.3 Replacing the Temperature Probe...................................................................................1-8
1.8.4 Replacing the Hi-Limit Thermostat in Fryers with Thermostat Controls.......................1-9
1.8.5 Replacing the Hi-Limit Thermostat in Fryers with Other Than Thermostat Controls .1-10
1.8.6 Replacing the Heat Mode Indicator Light in Fryers with Thermostat Controls ...........1-10
1.8.7 Replacing the Power or Melt Cycle Switch in Fryers with Thermostat Controls ........1-11
1.8.8 Replacing the Melt Cycle Timer in Fryers with Thermostat Controls .........................1-11
1.8.9 Replacing Burner Ceramic Targets...............................................................................1-12
1.8.10 Replacing the Gas Valve...............................................................................................1-12
1.8.11 Replacing the Pilot Assembly or Thermopile ...............................................................1-13
1.8.12 Replacing the Frypot.....................................................................................................1-14
1.9
Troubleshooting and Problem Isolation........................................................................1-15
1.9.1 Ignition Failures ............................................................................................................1-16
1.9.2 Improper Burner Functioning .......................................................................................1-17
1.9.3 Improper Temperature Control .....................................................................................1-18
1.9.4 Computer-Related Problems .........................................................................................1-19
1.9.5 Filtration Problems........................................................................................................1-20
1.9.6 Leakage Problems .........................................................................................................1-22
1.9.7 Basket Lift Malfunctions ..............................................................................................1-22
1.9.8 Interpretation of Digital Controller Lights....................................................................1-28
1.10
Troubleshooting Guides................................................................................................1-28
1.10.1 Troubleshooting the 24 VAC Circuit in Units without Interface Boards .....................1-29
1.10.2 Troubleshooting the 24 VAC Circuit in Units with Interface Boards ..........................1-30
1.10.3 Troubleshooting the Gas Valve ....................................................................................1-32
1.10.4 Troubleshooting the Thermostat ...................................................................................1-33
1.10.5 Troubleshooting the Temperature Probe ......................................................................1-34
Probe Resistance Chart .................................................................................................1-35
1.11 Wiring Diagrams..............................................................................................................1-36
i
CHAPTER 2: Parts List
Accessories .................................................................................................................................. 2-1
Basket Lift Assemblies and Component Parts............................................................................. 2-2
Bell Crank Basket Lift............................................................................................................. 2-2
Modular Basket Lift ................................................................................................................ 2-4
Burner Assembly Component Parts............................................................................................. 2-6
Cabinet Assemblies and Component Parts .................................................................................. 2-8
Fryer and Spreader Cabinet Assembly Components............................................................... 2-8
Filter Magic II Add-On Cabinet Components....................................................................... 2-12
Casters, Legs, and Associated Hardware................................................................................... 2-14
Component Shield and Filter Box Assemblies and Component Parts....................................... 2-15
Control Panel Assemblies, Flue Caps, Top Caps, and Related Items........................................ 2-20
Controller Assemblies (Thermostat Controllers)....................................................................... 2-22
Controller Assemblies (Other than Thermostat Controllers)..................................................... 2-24
Door Assembly .......................................................................................................................... 2-25
Drain and Filtration System Components.................................................................................. 2-26
Filter Magic II Square Drain Components ............................................................................ 2-26
Filter Magic II Filter Pan Assemblies ................................................................................... 2-28
Frypot Assemblies and Component Parts .................................................................................. 2-29
Oil Return Plumbing and Handle Assemblies ........................................................................... 2-30
Power Shower Assembly ........................................................................................................... 2-33
Temperature Probe, Thermostats, and Related Components..................................................... 2-34
Wiring Assemblies/Harnesses and Remote Cable Assemblies ................................................. 2-35
Wiring Connectors, Pin Terminals, and Power Cords............................................................... 2-36
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45 SERIES GAS FRYERS SERVICE AND PARTS MANUAL
CHAPTER 1: SERVICE PROCEDURES
1.1
Functional Description
The 45 Series fryers contain a welded steel (stainless or cold rolled) frypot that is directly heated by
gas flames that are diffused evenly over its lower surface by ceramic targets.
The flames originate from orifices in a U-shaped burner manifold positioned beneath the frypot.
The orifice diameters differ for natural and propane gas as indicated in the table below (see Page 2-7
for a complete list of available orifices).
45 Series Orifice Sizes (0-1999 ft/609 m)
Gas
Inches
Millimeters
Natural
0.057
1.45
Propane
0.034
0.86
Gas flow to the manifold is regulated by an electromechanical gas valve. This series of fryers is
equipped with a 24-volt gas valve and all models use a pilot ignition system.
PILOT IGNITION SYSTEM
The pilot ignition system is comprised of the pilot orifice, pilot hood, and a thermopile. The pilot
serves two purposes. The first is to light the burner, the second is to heat the thermopile. In operation, the thermopile is in contact with the pilot flame and generates millivolts. The millivolt output
passes through a normally closed high-limit switch and energizes the gas valve pilot coil, which in
turn opens the pilot valve. If the pilot flame is extinguished, voltage is lost to the gas valve pilot coil
and the pilot valve closes. A separate 24-volt circuit, activated by the fryer ON/OFF switch, provides voltage through the thermostat or controller to the gas valve main coil, which opens the main
valve. The gas valve is constructed so that the main valve will not open if the pilot valve is not
open. The pilot flame must be manually lit (either with a match or with an optional built-in piezo
igniter) when the fryer is first placed into operation.
ON/OFF
Switch
Line Voltage
Controlling Thermostat
or
Controller
Line Voltage
Main Coil
24 VAC
Transformer
Gas Valve
High-Limit
Thermostat
Pilot Coil
Thermopile
Pilot
The Pilot System
1-1
CONTROL OPTIONS
45 Series fryers may be equipped with thermostat controllers, analog controllers, digital controllers,
basket lift timers, or Computer Magic computers.
In fryers equipped with thermostat controls, the fryer and melt cycle are turned on and off by means
of rocker switches and the temperature is set by means of a knob connected directly to the frypotmounted thermostat. These units have no interface board. In this type of unit, 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 frypot is at setpoint temperature.
Fryers equipped with other types of controllers have an interface board located in the component
shield behind the control panel.
INTERFACE BOARDS
The interface board provides the link between the controller/computer and the fryer’s individual
components without requiring excessive wiring, and allows the controller to execute commands
from one central point. When built, depending upon the configuration of the particular fryer, any
one of three different boards may be used. Regardless of the particular board installed when the
fryer was built, P/N 806-3548 is the universal replacement part.
1
4
7
10
13
3
6
9
12
2
5
8
11
14
2
5
8
11
3
6
9
12
15
1
4
7
10
NOTES:
1. RELAYS K1 AND K2 ARE FOR BELL CRANK BASKET LIFTS. THEY ARE NOT PRESENT ON
BOARDS 806-5490 (U.S. AND NON-CE EXPORT UNITS W/O BASKET LIFTS) OR 806-7501
(CE UNITS, WITH OR WITHOUT BASKET LIFTS).
2. RESISTORS R1, R10, AND R15 ARE NOT USED ON ANY OF THE THREE BOARDS.
3. RESISTORS R11 AND R12 ARE NOT USED ON 806-5490 BOARDS.
INTERFACE BOARDS 806-3548, 806-5490, AND 806-7505
1-2
FREQUENTLY USED TEST POINTS FOR 45 SERIES INTERFACE BOARDS
Meter
Setting
Pins
Results
Test
12 VAC Power to Controller
50 VAC Scale
1 and 3 of J2
12-18
24 VAC Power
50 VAC Scale
24 VAC Terminals
22-28
24 VAC Power to Gas Valve
50 VAC Scale
6 on J1 and GROUND
22-28
120 VAC Power
250 VAC Scale
7 and 12 of J1
110-125
Probe Resistance*
R x 1000 OHMS 2 and 3 of J1
**
** Disconnect 15-Pin harness from controller before testing probe circuit.
** See Probe Resistance Chart at end of chapter.
Four LEDs, arranged across the top of the boards and identified in the table below, are provided to
assist in troubleshooting.
45 SERIES INTERFACE BOARD
LED DIAGNOSTIC LIGHTS
GV Indicates 24 VAC to the gas valve
AL Indicates open Drain Safety Switch (if installed)
24V Indicates 24 VAC from transformer
COMP Indicates 12 VAC to computer
Every board contains one heat relay (K3), and may contain two basket lift relays (K1 and K2). As
shipped from the factory, fryers with bell crank basket lifts will have relays K1, K2, and K3. All
other factory-original fryers will have boards with only relay K3.
THERMOSTATS AND TEMPERATURE PROBES
Different types of thermostats are used in 45 Series fryers, depending on the fryers’ configuration.
Fryers equipped with Thermostat Controls have an adjustable controlling (operating) thermostat.
The temperature at which the thermostat opens and closes is adjusted by physically changing the setting of the thermostat itself by means of an attached knob. When new, the Fenwal controlling thermostat used in 45 Series fryers is sensitive to one-degree changes in temperature.
CAUTION
Fenwal thermostats are used in a number of Frymaster products. The thermostat for
the 45 Series is 4 inches long. Do not use 3-inch Fenwal thermostats in 45 Series
fryers.
Fryers equipped with all other type controls have a temperature probe. In these units, the probe
resistance varies directly with the temperature. That is, as the temperature rises, so does resistance
at a rate of approximately 2 ohms for every 1º (F or C). Circuitry in the controller monitors the probe
resistance and controls burner firing when the resistance exceeds or falls below programmed
temperatures (setpoints). The temperatures are programmed by means of a keypad on the face of the
controller.
All 45 Series fryers are equipped with a high-limit thermostat. In the event that the fryer fails to
properly control the oil temperature, the high-limit thermostat prevents the fryer from overheating to
the flash point. The high-limit thermostat acts as a normally closed power switch that opens when
1-3
exposed to temperatures in the range of 425ºF to 450ºF (218ºC to 232ºC). The high-limit thermostat
is the same for CE and Non-CE applications, but the terminals for attaching it to Robertshaw and
Honeywell gas valves differ. When a replacement high-limit thermostat is ordered, make sure the
kit appropriate for the valve in use is ordered.
1.2
Accessing Fryers for Servicing
DANGER
Moving a fryer filled with cooking oil/shortening may cause spilling or splattering of
the hot liquid. Follow the draining instructions in Chapter 4 of the 45 Series Gas
Fryer Installation and Operation Manual before attempting to relocate a fryer for
servicing.
1. Shut off the gas supply to the unit. Unplug the power cord(s). Disconnect the unit from the gas
supply.
2.
Remove any attached restraining devices.
3.
Relocate the fryer 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
Checking the Burner Manifold Gas Pressure
WARNING
This task should be performed by qualified service personnel only.
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 (see illustration below for location)
and connect a gas pressure-measuring device to the port.
Remove this plug and connect a gas
pressure-measuring device to the port.
3. Place the gas valve in the ON position then place the fryer power switch in the ON position.
When the burner lights and continues to burn, compare the pressure reading to that for the corresponding gas in the tables on the following page.
1-4
CE Standard
Burner Manifold Gas Pressures
Pressure
(mbar)
Gas
Natural Gas Lacq
(G20) under 20 mbar
Natural Gas Gronique *
(G25) under 25 mbar
Natural Gas Gronique
(G20) under 20 mbar
Propane
(G31) under 37 or 50 mbar
Non-CE Standard
Burner Manifold Gas Pressures
Gas
Natural
Propane
Pressure
3.5" W.C.
0.73 kPa
8.25" W.C.
2.05 kPa
7,5
10
10
20,6
* Belgian G25 = 7,0 mbar
4. If the measured gas pressure does not match the appropriate pressure in the tables above, remove
the cap from the gas valve regulator and adjust to the correct pressure.
Robertshaw Valve
(Non-CE Units)
Honeywell Valve
(Non-CE Units)
Honeywell Valve
(CE Units)
Regulator Adjustment Screw Cap
5. Place the fryer power switch and the gas valve in the OFF position. Remove the fitting from the
pressure tap hole and reinstall the plug. Place the gas valve in the ON position, and check for and
eliminate any gas leaks. Place the gas valve in the OFF position.
1.4
Adjusting the Pilot Flame
1. On non-CE valves, remove the cap covering the pilot adjustment screw. On all valves, turn the
pilot adjustment screw counterclockwise to increase the length of the flame or clockwise to decrease the length of the flame. Adjust the flame to a length of 1 to 1½ inches (25 to 38mm).
To access the pilot adjustment screw on
Non-CE valves, this cap must be removed.
Robertshaw Valve
(Non-CE Units)
Pilot Adjustment Screw
Honeywell Valve
(Non-CE Units)
2. On Non-CE valves, reinstall the pilot adjustment screw cap.
1-5
Honeywell Valve
(CE Units)
1.5
Cleaning the Gas Valve Vent Tube
1. Carefully unscrew the vent tube from the gas valve. NOTE: The vent tube may be straightened
for ease in removal.
2. Pass a piece of ordinary binding wire (.052 inch diameter) or equivalent through the tube to remove any obstruction.
3. Remove the wire, then blow through the tube to ensure it is clear.
4. Reinstall tube and bend it so that the opening is pointing downward.
1.6
Adjusting Burner Ceramic Target Spacing and Alignment
DANGER
Drain the frypot or remove the handle from the drain valve before proceeding further.
Proper spacing of the top edge of the burner ceramic targets is ¾ inch (13 mm) from the frypot side.
To adjust target spacing, bend the brackets to which they are attached away or toward the frypot to
the proper distance. (A length of board of the proper thickness is useful as a gauge to verify spacing
and alignment.)
1.7
Calibrating the Thermostat Control
NOTE: The fryer control panel must be hinged down from the control panel mounting frame to perform thermostat calibration. In order to hinge the control panel down, the thermostat knob must be
removed from its shaft. It is secured with a setscrew located opposite the index mark on the knob.
1. Fill the frypot to the lower OIL-LEVEL line with cooking oil/shortening. If solid shortening is
used, it must be pre-melted before starting the calibration procedure.
2. Ensure the fryer ON/OFF Switch is in the OFF position, then light the pilot. (Refer to Chapter 3
of the 45 Series Gas Fryer Installation and Operation Manual for detailed lighting instructions.)
3. Insert a good grade 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 flexible shaft. Remove
the extension to expose the slot in the end of the flexible shaft.
Stop screw
Locking nut
5. Place the fryer ON/OFF switch in the ON position.
NOTE: If the burner does not light at this time, it
does not mean the thermostat is defective!
Setscrew
Use a small flat-tipped screwdriver to slowly turn the flexible shaft counterclockwise until the
burner lights. Turning the shaft counterclockwise causes the burner to light and clockwise
causes it to shut off.
1-6
6. When the cooking oil/shortening temperature reaches 325ºF (162ºC), turn the flexible shaft
slowly clockwise until the burner shuts off.
7. Allow the fryer to sit for a few minutes, then slowly turn the flexible shaft counterclockwise until the burner lights.
8. Repeat steps 6 and 7 at least three times to ensure an accurate setting is obtained. The Thermostat Control is considered to be properly calibrated when the burner lights as the cooking
oil/shortening cools to 325ºF (162ºC)—not when the burner shuts off as the temperature rises.
9. Once the calibration point of 325ºF (162ºC) is determined, allow the burner to cycle on and off at
least 3 times to be sure it will light at the calibrated temperature.
10. After the calibration is complete, place the fryer power switch in the OFF position and disconnect the fryer from the electrical supply.
11. Carefully replace the thermostat shaft extension, ensuring that the stop screw is pointed straight
up. Tighten the stop screw and locking nut and the setscrew, being careful not to rotate the flexible shaft.
CAUTION
The thermostat flexible shaft must not be rotated while installing the thermostat
shaft extension!
When handling the thermostat, do not rotate the shaft more than two turns in either
direction. Doing so will cause damage to the thermostat.
12. Close the fryer control panel and replace the screws the upper corners.
13. Reinstall the thermostat knob with its pointer aligned with the 325ºF (162ºC) index mark on the
temperature dial.
14. Reconnect the fryer to the electrical supply.
1.8
Replacing Fryer Components
1.8.1 Replacing the Controller or Computer
Unplug
harness
1. Disconnect the fryer from the electrical power
supply.
2. Unscrew the two control panel screws. The
control panel is hinged at the bottom and will
swing open from the top.
3. Unplug the fryer wiring harness from the back
of the controller/computer and disconnect the
grounding wire.
1-7
Disconnect
grounding wire
4. Remove the controller/computer by lifting it from the hinge slots in the fryer control panel
frame.
5. Reverse the procedure to install a new controller/computer.
1.8.2 Replacing the Operating Thermostat
CAUTION
The thermostat must be calibrated after installation is complete. Refer to Section 1.7
for calibration instructions.
When handling the thermostat, do not rotate the shaft more than two turns in either
direction. Doing so will cause damage to the thermostat.
1. Disconnect the fryer from the electrical supply and drain the frypot.
2. 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 is hinged at the bottom and will swing open from the top.
3. Disconnect the 9-Pin connector and remove the control panel from the fryer by disengaging its
tabs from the hinge slots in the mounting frame.
4. Loosen the setscrews securing the flexible shaft
to the thermostat shaft and slip the flexible shaft
off the thermostat shaft.
Loosen these setscrews and slip the
flexible shaft off the thermostat shaft.
5. Remove the flexible shaft guide by removing
the two sheet metal screws securing it to the upper frame.
6. Disconnect the thermostat leads from Pin 14 in
the 20-pin terminal block and from the gas
valve terminal.
NOTE: If the fryer is configured with a melt cycle, the thermostat leads will be connected to the
melt cycle timer motor or PC board rather than to the terminal block and gas valve. Disconnect
the leads from the motor or PC board if this is the case.
7. Unscrew the thermostat from the frypot and remove.
8. Apply Loctite™ PST56765 thread sealant or equivalent to the replacement thermostat threads.
9. Reverse steps 1 through 7 to install the replacement.
1.8.3
Replacing the Temperature Probe
1. Disconnect the fryer from the electrical supply.
1-8
2. Drain the frypot.
3. Remove the screws from the upper left and
right corners of the control panel. The panel
is hinged at the bottom and will swing open
from the top.
Unplug
harness
4. Unplug the wiring harness from the back of
the controller and disconnect the grounding
wire.
5. Remove the controller from the fryer by liftDisconnect
ing it from the hinge slots in the control panel
grounding wire
frame.
6. Remove the two screws from the base of the interface board mounting bracket.
7. Disconnect the 12-pin plug from the back of the interface board and lay the board in the left end
of the compartment with all other wires still connected.
8. Remove the 12-volt transformer from the component shield and lay it in the left end of the compartment with wires still connected.
9. Using a pin-pusher, remove the temperature probe wires (pins 1 and 2) from the 12-pin plug disconnected in step 7.
10. Unscrew the temperature probe from the frypot and remove.
11. Apply Loctite™ PST56765 thread sealant or equivalent to new probe threads.
12. Reverse steps 1 through 10 to install the replacement probe.
1.8.4 Replacing the High-Limit Thermostat in Fryers with Thermostat Controls
1. Disconnect the fryer from the electrical supply.
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 is hinged at the bottom and will swing open from the top.
4. Disconnect the 9-Pin connector and remove the control panel from the fryer by disengaging its
tabs from the hinge slots in the mounting frame.
6. Disconnect the high-limit thermostat leads from the gas valve pilot coil.
7. Unscrew the high-limit thermostat from the frypot and remove.
8. Apply Loctite™ PST56765 thread sealant or equivalent to the replacement thermostat threads.
9. Reverse steps 1 through 7 to install the replacement.
1-9
1.8.5 Replacing the High-Limit Thermostat in Fryers with Other Than Thermostat
Controls
1. Disconnect the fryer from the electrical power
supply.
Unplug
harness
2. Drain the frypot.
3. Remove the screws from the upper left and
right corners of the controller panel. The controller is hinged at the bottom and will swing
open from the top.
4. Unplug the wiring harness and disconnect the
grounding wire from the the controller.
Disconnect
grounding wire
5. Remove the controller from the fryer by lifting it from the hinge slots in the fryer control panel
frame.
6. Remove the two screws from the base of the interface board mounting bracket.
7. Disconnect the 12-pin plug from the back of the interface board and lay the board in the right
end of the compartment with all other wires still connected.
8. Remove the 12-volt transformer and lay it in the right end of the compartment with wires still
connected.
9. Remove the high-limit thermostat wires from the gas valve pilot coil and pull them up through
the control shield.
10. Unscrew the high-limit thermostat from the frypot and remove.
11. Apply Loctite™ PST56765 thread sealant or equivalent to the replacement thermostat’s threads
and screw it into the frypot.
12. Attach the appropriate terminals (furnished in the replacement thermostat kit) to the thermostat
leads.
13. Reverse steps 1 through 9 to complete installation of the replacement thermostat.
1.8.6 Replacing the Heat Mode Indicator Light in Fryers with Thermostat Controls
1.
Disconnect the fryer from the electrical supply.
2.
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 is hinged at the bottom and will swing open from the top.
1-10
3.
Disconnect the 9-pin connector and remove the control panel from the fryer by disengaging its
tabs from the hinge slots in the mounting frame.
4.
Carefully press the light out from the back of the control panel. Disconnect one wire at a time
and reconnect it to the replacement light until all wires are transferred.
5.
Carefully press the light back into the control panel.
6.
Reverse steps 1-3 to reassemble the fryer.
1.8.7 Replacing the Power or Melt Cycle Switch in Fryers with Thermostat Controls
1.
Disconnect the fryer from the electrical supply.
2.
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 is hinged at the bottom and will swing open from the top.
3.
Disconnect the 9-pin connector and remove the control panel from the fryer by disengaging its
tabs from the hinge slots in the mounting frame.
4.
Using a flat-tipped screwdriver, disconnect the chrome bezel from the tabs on the switch and
press the switch out from the front.
5.
Carefully press the new switch back into the chrome bezel, making sure the tabs on the switch
engage the slots in the bezel.
6.
Disconnect one wire at a time from the old switch and reconnect it to the new switch until all
wires have been transferred.
7.
Reverse steps 1-3 to reassemble the fryer.
1.8.8 Replacing the Melt Cycle Timer in Fryers with Thermostat Controls
NOTE: In early 1999, PC board melt cycle timers replaced melt cycle timer motors in new fryers.
1. Disconnect the fryer from the electrical supply.
2. 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 is hinged at the bottom and will swing open from the top.
3. Remove the screws securing the timer motor (or the PC board timer bracket) to the fryer (see illustration on Page 2-16).
4. Remove one wire at a time and reconnect it to the replacement PC board timer until all wires
have been transferred.
5. Reverse steps 1-3 to reassemble the fryer.
1-11
1.8.9 Replacing Burner Ceramic Targets
DANGER
Drain the frypot or remove the handle from the drain valve before proceeding further.
1.
Disconnect fryer from electrical and gas supplies.
2.
On FM45 fryers, remove square-drain sections as necessary to expose burner.
3.
Disconnect the wires from the gas valve terminal block, marking each wire to facilitate reconnections.
4.
Remove the high-limit thermostat wires from the gas valve pilot coil.
5.
Disconnect the pipe union collar at the right side of the gas valve.
6.
Remove the burner heat shield hanger screws at the front of the burner and remove the heat
shield.
7.
Remove the burner hanger screws and lower the front of the main burner. Pull it forward to
clear the rear burner hanger, then lower the burner to the floor.
8.
Raise the front of the fryer enough to slide the burner from under the fryer cabinet.
9.
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 orifices that hold the assembly to the burner manifold. Position the new assembly and replace the orifices.
WARNING
Use extreme care to prevent cross-threading and stripping when reinstalling the
brass orifices.
10. Reverse steps 1-8 to reinstall the burner assembly. Check spacing and alignment of targets in
accordance with Section 1.5.
1.8.10 Replacing the Gas Valve
DANGER
Drain the frypot or remove the handle from the drain valve before proceeding further.
1. Disconnect fryer from electrical and gas supplies
1-12
2. Disconnect the wires from the gas valve terminal block, marking each wire to facilitate reconnections.
3. Remove the high-limit thermostat wire from the gas valve pilot coil.
4. Disconnect the pilot gas line fitting from the gas valve.
5. Disconnect the pipe union collars to the left and right of the gas valve and remove the valve.
6. Remove the pipe fittings from the old gas valve and install on the replacement valve, using Loctite™ PST56765 or equivalent pipe thread sealant on threads.
7. Reverse steps 1-5 to install the replacement gas valve.
1.8.11 Replacing the Pilot Assembly or Thermopile
DANGER
Drain the frypot or remove the handle from the drain valve before proceeding further.
1.
Remove the burner assembly in accordance with steps 1-8 of Section 1.8.9.
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 fitting from the
gas valve pilot coil.
c. Reverse steps a and b to install the replacement thermopile.
Bend clip to release
thermopile.
3. To replace the complete pilot assembly:
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 fitting from the gas valve pilot coil.
d. Reverse steps a through c to install the replacement pilot assembly.
4. Reinstall the burner assembly by reversing steps 1-8 of Section 1.8.9.
1-13
1.8.12 Replacing the Frypot
1. Drain the frypot.
2. Remove all accessories (e.g., frypot covers, basket lift arms, etc.) from the fryer.
3. Disconnect the fryer from gas and electrical supplies.
4. Remove the screws from the top cap above the control panel and lift it up and off the fryer(s).
5. If the fryer is equipped with other than a thermostat control, skip to Step 10.
6. Loosen the setscrew securing the thermostat knob to the thermostat flexible shaft and remove the
knob. Remove the screws from the upper left and right corners of the control panel. Disconnect
the 9-pin connector and remove the control panel from the fryer.
7. Loosen the setscrews securing the flexible
shaft to the thermostat shaft and slip the flexible shaft off the thermostat shaft.
Loosen these setscrews and slip
flexible shaft off the thermostat shaft.
8. Remove the flexible shaft bracket from the
fryer by removing the two sheet metal screws
securing it to the upper frame.
9. Disconnect the thermostat leads from Pin 14
in the 20-pin terminal block and from the gas
valve terminal. Mark each wire to facilitate
reconnection. Skip to Step 14.
NOTE: If the fryer is configured with a melt cycle, the thermostat leads will be connected to
the melt cycle timer motor rather than to the terminal block and gas valve. Disconnect the leads
from the motor if this is the case.
CAUTION
When handling the thermostat, do not rotate the shaft more than two turns in either
direction. Doing so will cause damage to the thermostat.
10. For fryers equipped with other than Thermo- move the temperature probe leads (pins 1
and
stat Controls, remove the screws from the upper left and right corners of the control panel.
Unplug the wiring harness from the back of
the controller and disconnect the grounding
wire. Remove it from the fryer by lifting it
from the hinge slots in the fryer control frame.
Unplug
harness
11. Remove the two screws from the base of the
interface board bracket.
12. Disconnect the 12-pin plug from the back of
the interface board. Use a pin pusher to re-
1-14
Disconnect
grounding wire
2) and the high-limit thermostat leads (pins 6 and 8) from the plug. Leave all other wires connected. Leave the interface board lying on the shield.
13. Remove the louvered frame above the control panel opening.
14. Remove the screws securing the component shield to the fryer.
15. Disconnect the wires from components in component shield and mark to facilitate reconnection.
16. Disconnect the wires from the gas valve terminal block. Mark each wire to facilitate reconnection.
17. Remove the cover from the safety drain switch, disconnect the wires from the switch, and pull
them out of the switch box.
18. 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.
19. Disconnect the pipe union on the right side of the gas valve.
20. On FM45 fryers, remove the section of square drain from the drain valve of the frypot to be removed.
21. Remove the frypot hold down bracket.
22. Remove the screws from the flue cap sides and back and lift it clear of the fryer(s).
23. Remove the oil return line from the front of the frypot to be removed.
24. Lift the complete frypot assembly (frypot, burner, gas valve, and flue) from the fryer cabinet.
25. Transfer the burner heat shield and burner to the replacement frypot.
26. Remove the drain valve, thermostat or temperature probe, and high-limit thermostat and install
on replacement frypot.
CAUTION
Before installing the thermostat/temperature probe, high-limit thermostat, and drain valve
on the replacement frypot, clean their threads and apply Loctite™ PST56765 thread
sealant or equivalent to the threads.
27. Reverse steps 1-25 to reassemble the fryer.
1.9
Troubleshooting and Problem Isolation
Because it is not feasible to attempt to include in this manual every conceivable problem or trouble
condition that might be encountered, 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 correct any problem encountered.
1-15
Problems you are likely to encounter can be grouped into seven broad categories:
1.
2.
3.
4.
Ignition failures
Improper burner functioning
Improper temperature control
Computer-related problems
5. Filtration problems
6. Leakage problems
7. Basket lift malfunctions
The probable causes of each category are discussed in the following sections. A series of Troubleshooting Guides (decision trees) is also included at the end of the chapter to assist in identifying
some of the more common problems.
1.9.1 Ignition Failures
Ignition failures occur when the 24VAC power supply to the gas valve is interrupted, when the gas
supply is interrupted, or when the pilot flame is extinguished.
Solid-state controllers indicate ignition failure by illuminating the heat light and trouble light simultaneously. All other controllers give no specific indication of an ignition failure.
There are three primary reasons for ignition failure, listed in order of probability:
1. Problems related to the gas and/or electrical power supplies.
2. Problems related to the electronic circuits.
3. Problems related to the gas valve.
PROBLEMS RELATED TO THE GAS AND/OR ELECTRICAL POWER SUPPLIES
The main indicators of this are that 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.
PROBLEMS RELATED TO THE ELECTRONIC CIRCUITS
If gas and electrical power are being supplied to the fryer, 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 Filter
Magic II filtration system, first verify that the drain valve is fully closed. (The valve is attached to a
microswitch that 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 does not have a filtration system, refer to the troubleshooting guides TROUBLESHOOTING THE
24 VAC CIRCUIT.
PROBLEMS RELATED TO 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 itself,
but before replacing the gas valve refer to TROUBLESHOOTING THE GAS VALVE on page 1–32.
1-16
1.9.2 Improper Burner Functioning
With problems in this category, the burner ignites but exhibits abnormal characteristics such as
“popping,” incomplete lighting of the burner, fluctuating flame intensity, and flames “rolling” out of
the fryer.
“Popping” indicates delayed ignition. In this condition, the main gas valve is opening but the burner
is not immediately lighting. When ignition does take place, the excess gas “explodes” into flame,
rather than smoothly igniting.
The primary causes of popping are:
•
•
•
•
•
•
Incorrect or fluctuating gas pressure
Misdirected or weak pilot flame
Burner deflector targets out of alignment or missing
Clogged burner orifices
Inadequate make-up air
Clogged vent tube, causing incorrect gas pressure
If popping occurs only during peak operating hours, the problem may be incorrect or fluctuating gas
pressure. Verify that the incoming gas pressure (pressure to the gas valve) is in accordance with the
appropriate CE or Non-CE Standard found in the table below, and that the pressure remains constant
throughout all hours of usage. Refer to Checking the Burner Manifold Pressure (Section 1.3) for
the procedure to checking the pressure of gas supplied to the burner.
CE Standard
for Incoming Gas Pressures
Non-CE Standard
for Incoming Gas Pressures
Gas
Natural
LP
Minimum
6" W.C.
1.49 kPa
14.93 mbar
Maximum
14" W.C.
3.48 kPa
34.84 mbar
11" W.C.
2.74 kPa
27.37 mbar
14" W.C.
3.48 kPa
34.84 mbar
Pressure
Gas
G20
(mbar)(1)
20
Orifice Diameter
18 x 1,40 mm
Regulator
Pressure
7,5 mbar
Consumption
3,00 m3/h
G25
20 - 25
18 x 1,40 mm
10 mbar
3,50 m3/h
G31
37 - 50
18 x 0,86 mm
20,6 mbar
2,21 kg/h
2
(1) mbar = 10,2 mm H O
If popping is consistent during all hours of operation, verify that the pilot is properly positioned
above the burner orifice and that the pilot pressure is correct. Correct pilot pressure is indicated by a
flame 1 to 1½” (25 to38 mm) long. Refer to Section 1.6 for the pilot flame adjustment procedure.
Clogged burner orifices, especially those near the pilot, are also likely causes of delayed ignition.
Clogged orifices are indicated by no flame, flames that are orange-colored, and flames that shoot out
at an angle from the rest.
Another cause of popping is an insufficient air supply or drafts that are blowing the pilot flame away
from the burner. Check for “negative pressure” conditions in the kitchen area. If air is flowing into
the kitchen area, this indicates that more air is being exhausted than is being replenished and the
burners may be starved for air.
1-17
If the fryer’s gas and air supplies are okay, the problem most likely is with one of the electrical components. Examine the controller for signs of melting/distortion and/or discoloration due to excessive
heat buildup in the fryer. (This condition usually indicates improper flue performance.). A discolored or distorted controller is automatically suspect and should be replaced. However, unless the
condition causing excessive heat in the fryer is corrected, the problem is likely to recur.
The burner lighting on one side only may be caused by a missing or misaligned rear deflector target
or improper burner manifold pressure. Clogged burner orifices are usually the cause of gaps in
burner firing.
Fluctuating flame intensity is normally caused by either improper or fluctuating incoming gas pressure, but may also be the result of variations in the kitchen atmosphere. Verify incoming gas pressure in the same way as for “popping,” discussed in the preceding paragraphs. Variations in the
kitchen atmosphere are usually caused by air conditioning and/or ventilation units starting and stopping during the day. 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 airflow patterns that may affect
flame intensity.
Flames “rolling” out of the fryer are usually an indication of negative pressure in the kitchen. Air
is being sucked out of the fryer enclosure and the flames are literally 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, Checking the Burner Manifold Pressure. An obstructed flue, which prevents
the fryer from properly exhausting, may also be the cause.
An excessively noisy burner, especially with flames visible above the flue opening, may indicate
that the burner gas pressure is too high, or it may simply be that the gas valve vent tube is blocked.
If the gas pressure is correct and the vent tube in unobstructed, the gas valve regulator is probably
defective.
Occasionally a burner may apparently be operating correctly; nevertheless, the fryer has a slow recovery rate. (The recovery rate is the length of time required for the fryer to increase the oil temperature from 250ºF to 300ºF (121ºC to 149ºC)). The primary causes of this are low burner manifold pressure and/or misaligned or missing deflector targets. If both of these causes are ruled out,
the probable cause is a gas valve regulator that is out of adjustment. Refer to Checking the Burner
Manifold Pressure in Section 1.3.
1.9.3 Improper Temperature Control
Temperature control, including the melt cycle, is a function of several interrelated components, each
of which must operate correctly. The principle component is the thermostat (in thermostat control
units) or the temperature probe (in fryers equipped with other types of controllers). Depending
upon the specific configuration of the fryer, other components may include the interface board and
the controller.
Improper temperature control problems can be categorized into melt cycle problems and failure to
control at setpoint problems.
1-18
MELT CYCLE PROBLEMS
In fryers equipped with thermostat controls, the melt cycle is controlled by a mechanical timer.
There are three components that may fail: the melt cycle timer itself, the melt cycle timer microswitch, or the control panel melt cycle ON/OFF switch. In all cases, the defective component
must be replaced.
In fryers equipped with other types of controllers, the problem may be with the controller itself, the
temperature probe, or a malfunctioning heat relay on the interface board.
For problem isolation techniques, refer to the troubleshooting guides TROUBLESHOOTING THE
THERMOSTAT and TROUBLESHOOTING THE TEMPERATURE PROBE.
FAILURE TO CONTROL AT SETPOINT
In fryers equipped with thermostat controls, the problem will be with the thermostat itself. Possible
causes are that the thermostat is out of calibration, the knob or flexible shaft is loose on the thermostat shaft, a thermostat wire is disconnected or broken, or the thermostat is defective. Refer to Section 1.7 for instructions on calibrating the thermostat.
In fryers equipped with other types of controls, the problem may be with the temperature probe, the
interface board, or the controller. Refer to the troubleshooting guide TROUBLESHOOTING THE
TEMPERATURE PROBE for problem isolation techniques.
1.9.4 Computer-Related Problems
COMPUTER MAGIC FEATURES
SENSITIVITY OR “STRETCH AND SHRINK TIME”
Sensitivity or stretch time is a programmable feature, patented by Frymaster that increases or
decreases the cook time countdown based on variations in the oil temperature from the set point.
The sensitivity for each product button has ten settings (0 through 9). A zero sensitivity setting will
disable the feature (no change in cooking time), while a nine will provide the highest sensitivity or
most change. The correct sensitivity for any product is based on the product, its density, the set
point temperature, and the customer’s own requirements.
RECOVERY TIME
Recovery time or rate of rise is a method of measuring a fryer’s performance. Put simply, it is the
time required for the fryer to increase the oil temperature from 250ºF to 300ºF (121ºC to 149ºC).
This range is used as a standard since ambient kitchen temperatures can effect the test if lower
ranges are used.
The Computer Magic performs the recovery test each day as the fryer warms up. An operator can
view the results of the test any time the fryer is above the 325ºF (163ºC) point by pressing the
button and entering the code 1652. The test results will be displayed in the computer’s LED panel in
minutes and seconds. The acceptable recovery time for 45 Series fryers is 2 minutes and 25 seconds.
1-19
COMMON COMPUTER COMPLAINTS
Most problems concerning computers have to do with programming them. There are four common
complaints. The complaints, their causes, and corrective actions are:
1. Fryer constantly displays “HI.”
Cause: Setpoint incorrect or missing.
Corrective Action: Press
in the setpoint.
1650, enter the correct setpoint using keypad, then press
to lock
2. Temperature is displayed in Celsius.
Cause: Computer is programmed to display in Celsius.
Corrective Action: Press
1658.
3. Temperature is constantly displayed.
Cause: Computer is programmed for constant temperature display.
Corrective Action: Press
165L.
4. Computer times down too slowly or too quickly.
Cause: Computer is compensating for oil temperature via the sensitivity setting.
Corrective Action: Reprogram sensitivity setting for each product in accordance with programming instructions in Chapter 3 of the 45 Series Gas Fryer Installation and Operation Manual.
1.9.5
Filtration Problems
The majority of filtration problems arise from operator error. One of the most common errors is
placing the filter paper on the bottom of the filter pan rather than over the filter screen.
Whenever the complaint is “the pump is running, but no oil is being filtered,” check the installation
of the filter paper, including that the correct size is being used. While you are checking the filter
paper, verify that the O-rings on the bottom of the filter pan and on the male disconnect (at inside
rear of filter cabinet) are present and in good condition. Missing or worn O-rings will allow the
pump to suck air and decrease its efficiency.
If the pump motor overheats, its thermal overload will trip and the motor will not start until it is reset. If the pump motor does not start, press the red reset switch located on the end of the motor nearest the operator. If the pump then starts, something caused the motor to overheat. It may be just that
several frypots were being filtered one after the other and the pump got hot. Letting the pump cool
down for at least a half-hour is all that is required in this case. More often, the pump overheated for
one of the following reasons:
•
Shortening was solidified in the pan or filter lines.
1-20
•
The operator attempted to filter oil or shortening that was not heated. Cold oil and shortening
are thicker and cause the pump motor to work harder and overheat.
If the motor tries to run but the pump does not, there is a blockage in the pump. Incorrectly sized or
installed paper will allow food particles and sediment to pass through the filter pan and into the
pump. When sediment enters the pump, the gears can bind up causing the motor to overload, again
tripping the thermal overload. Solidified shortening in the pump will also cause it to seize, with the
same result.
A pump seized by debris or hard shortening can
usually be freed by manually moving the gears
with a screwdriver or other instrument.
1.
Disconnect power to the filter system.
2.
Remove the input plumbing from the pump.
3.
Use a screwdriver to manually turn the gears.
•
•
Sediment
Particle
Oil Flow
Turning the pump gears backwards will
release a hard particle and allow its removal.
Sediment
Particle
Up for reverse
Down for
forward
Turning the pump gears forward will
push softer objects and solid shortening
through the pump and allow free movement of the gears.
Incorrectly sized or installed paper will also allow food particles and sediment to pass through and
clog the suction tube on the bottom of the filter carriage. Particles large enough to block the suction
tube may indicate that the crumb tray is not being used.
Pan blockage can also occur if shortening is left in the pan and allowed to solidify. The heater strip
on the suction tube is designed to prevent solidification of residual shortening left in the tube. It will
not melt or prevent solidification of shortening in the pan.
Blockage removal can be accomplished by forcing the item out with an auger or drain snake. Compressed air or other pressurized gases should not be used to force out the blockage.
Possible problems with the Power Shower include clogged openings, shortening solidified in the
tubes, missing clean-out plugs, and missing or worn O-rings. Cleaning the unit and replacing missing plugs and missing or worn O-rings will correct these problems.
The electronics of the Filter Magic II are simple and straightforward. Microswitches, attached to the
drain valve handles of each vat and wired in parallel, provide the 24 VAC needed to activate the
pump relay coil when the handles are moved to the ON position. The activated coil pulls in the
pump motor switch, supplying power to the motor.
1-21
The suction tube heater and flexible hose heater are wired directly into the 24VAC source. They
remain energized as long as the unit is plugged in.
Line VAC
Return Line Heater Tapes
24 VAC
Suction Tube (Pan) Heater Tape
Micro-switches
Pump Relay Coil
Pump Motor
M
Pump Motor Switch
Filter Magic Simplified Wiring Diagram
1.9.6 Leakage Problems
Leakage of the frypot almost always will be due to improperly sealed high limit switches, thermostats/temperature probes, and drain fittings. When installed or replaced, each of these components
must be sealed with Loctite PST56765 sealant or equivalent to prevent leakage. In very rare cases, a
leak may develop along one of the welded edges of the frypot. When this occurs, the frypot must be
replaced.
If the sides and/or ends of the frypot are coated with oil/shortening, the most likely cause is spillage
over the top of the frypot rather than leakage.
The clamps, which hold the drain tube sections together, may loosen over time as the tubes expand
and contract with heating and cooling during use. If the section of drain tube connected to the drain
valve is removed for whatever reason, make sure that its grommet is in good condition and properly
fitted around the nipple of the drain when it is reinstalled. Also, check to insure that the drain tube
runs downward from the drain along its whole length and has no low points where oil or shortening
may accumulate.
1.9.7 Basket Lift Malfunctions
45 Series fryers may optionally be equipped with automatic basket lifts to ensure uniform cooking
times. The lifts may be configured for manual control or for control via a Basket Lift Timer or
Computer Magic computer. Basket lifts will always come in pairs, although each operates independently.
In units configured for manual (push-button) controls, a mechanical or electrical timer controls voltage to the system. A rotary knob is turned to set the cook time, and pressing the button in the middle
of the knob activates the motor.
In units with Computer Magic or Basket Lift Timers, timing circuitry in the controller initiates and
stops basket lift operation depending upon the variables programmed by the operator. When the
1-22
product button is pressed, the timing circuitry activates a coil in the basket lift relay to supply power
to the motor.
There are two types of basket lifts: the “bell crank” design, and the “modular” design
A bell crank basket lift consists of a cam and
bell crank that are connected to the basket lift
arm by a flat metal link. The cam is attached
to a drive motor. The motor rotates the cam,
thus raising or lowering the lift arm linked to
the bell crank. A roller-activated microswitch
is used to limit travel. When the push-button
in the manual timer or the product button for
computers is pushed, the motor circuit is completed and the motor runs, lowering the basket. When the roller in the microswitch
makes or loses contact with the cam, the
switch is reversed and power to the motor is
cut. At the end of the specified cooking time,
the timer/controller reverses its switch position so that the motor circuit is again complete. The motor runs, raising the basket, until
contact with the cam is again made or lost.
Left bell crank and cam with basket lift link shown in the
down position. Note the microswitch in the upper right
corner.
Bell Crank Basket Lift
Simplified Schematic
LEFT BASKET
LIFT TIMER
C
RIGHT BASKET
LIFT TIMER
C
TM
TM
NO
NO
L
L
NC
NC
H
N
NC
NO
NO
NC
C
C
LEFT
MICROSWITCH
RIGHT
MICROSWITCH
M
M
LEFT BASKET
LIFT MOTOR
RIGHT BASKET
LIFT MOTOR
When the timer button is pushed, the NO circuit in the timer is closed,
supplying voltage through the microswitch to the motor. The bell
crank/cam rotates until switch postition in the microswitch is reversed,
stopping the motor with the basket in the down position. When the timer
reaches zero, the the switch in the timer reverts to the NC position. This
supplies power to the motor via the microswitch. Once again, rotation
of the bell crank/cam eventually causes the microswitch to reverse
itself, stopping the motor with the basket in the up position.
1-23
A modular basket lift consists of a toothed rod to which the basket lift arm is attached, a reversibledrive gear motor, and a pair of roller activated microswitches. The gear motor engages the teeth in
the rod, moving it up or down depending upon the direction of rotation of the motor. Microswitches
at the upper and lower limits of movement stop the motor when the basket is in the full up or full
down position and also reverse the direction of current flow thus reversing the motor direction.
When the manually set or programmed cooking time has elapsed, current is again supplied to the
basket lift and the basket is raised.
When the timer times-out, power is supplied to the opposite pole of the motor through the upper
microswitch. The motor drives the rod upward until it loses contact with the upper microswitch,
cutting power to the motor and stopping the lift.
In units configured for Basket Lift Timer Controllers or Computer Magic computers, the process is
almost identical. The difference is that the push button mechanical timer is replaced with timing circuitry in the computer or controller. The specific cook times (and other settings) are programmed
into the computer or controller by the operator. When the product button is pressed, the timing circuitry activates a coil in the basket lift relay to supply power to the lower microswitch. As with the
manually controlled units, the microswitches stop the motor at the lift’s upper and lower travel limits
and reverse the direction of current flow thus reversing the motor direction.
Problems with the basket lift system can be grouped into three categories:
• Binding/jamming problems
• Motor and gear problems
• Electronics problems
Manual (Push-Button)
Modular Basket Lift Simplified Schematic
H
2-Pole
Mech
Timer
1 or 5
Computer/Controller
Modular Basket Lift Simplified Schematic
N
H
N
N.O.
Upper Limit
Microswitch
N.O.
Upper Limit
Microswitch
M
5
3
M
6
4 or 6
1 or 4
N.C.
Lower Limit
Microswitch
3
Basket Lift
Relay
To computer/controller
via interface board
When the timer button is pushed, the lower circuit is activated,
causing the basket lift to be lowered, closing the normally open
upper microswitch. When the lower normally closed microswitch
is opened by the downward moving basket lift rod, power to the
motor is cut. When the timer times-out, the upper circuit is
activated, causing the basket lift to be raised, reclosing the lower
microswitch. When the basket lift rod clears the upper
micorswitch, allowing it to reopen, power to the circuit is cut and
the motor stops. Pushing the timer button again restarts the
cycle.
N.C.
Lower Limit
Microswitch
When the product button is pushed on the computer/controller,
current flows through a coil in the basket lift relay, causing the
lower circuit to be activated. This causes the basket lift to be
lowered, closing the normally open upper microswitch. When the
lower normally closed microswitch is opened by the downward
moving basket lift rod, power to the motor is cut. When the
computer/controller times-out, the current to the relay coil is cut,
allowing the upper circuit to be activated. This causes the basket
lift to be raised, reclosing the lower microswitch. When the basket
lift rod clears the upper micorswitch, allowing it to reopen, power
to the circuit is cut and the motor stops. Pushing the product
button again restarts the cycle.
1-24
230/240/250V Modular Basket Lift Assembly
BINDING/JAMMING PROBLEMS
Noisy, jerky or erratic movement of the lifts is usually due to lack of lubrication of the rods and their
bushings. Apply a light coat of Lubriplate™ or similar lightweight white grease to the rod and bushings to correct the problem.
Another possible cause of binding, in the case of modular basket lifts, is the improper positioning of
the motor, which prevents the gear from correctly engaging the teeth in the rod. To correct the
problem, loosen the screws that hold the motor in place and move it forward or backward until the
rod has just enough slack to be rotated slightly.
MOTOR AND GEAR PROBLEMS
In modular basket lift units, the most likely problem to be encountered in this category is erratic motion of the lift due to a worn drive gear. Failure to keep the lift rod and bushings properly lubricated
will cause unnecessary wear of the gear. The problem is corrected by replacing the worn gear.
If the lift cycles correctly but fails to remain in the up position (i.e., goes up, but then slowly settles
back down into the frypot), the problem is a failed motor brake. A failed motor brake cannot be repaired and requires replacement of the motor itself.
If power is reaching the motor but the motor fails to run, the motor is burned out and must be replaced.
1-25
ELECTRONICS PROBLEMS
This category encompasses problems with the relays, microswitches, capacitors, resistors, interface
board, wiring, and controls. Troubleshooting the electronics of both bell crank and modular basket
lifts is simply a process of verifying current flow through the individual components up to and including the motor. Using a multimeter set to the 250 VAC range, check the connections on both
sides of the component for the presence of 120 VAC.
The simplified wiring diagrams that follow identify the components and wiring connection points.
Bell Crank Basket Lift Simplified Wiring Diagram
CONTROL PANEL
LEFT TIMER
SPLICE
C
RIGHT TIMER
TM
TM
C
NO
NO
L
L
NC
NC
SPLICE
2
3
DISCONNECT
4
NO
5
NC
NC
1
NO
RIGHT
MICROSWITCH
LEFT
MICROSWITCH
C
LEFT M
6
C
GEAR MOTOR
TERMINAL
CONNECTOR
BASKET LIFT
1-26
M RIGHT
N
G
H
Modular Basket Lift Simplified Wiring Diagram
NOTE: References to right and left are from the rear of the fryer.
RIGHT SIDE
LEFT SIDE
BLK
BLK
12.5 μ F
BRN 1
RED 1
RESISTORS
(either 2 or 6
depending on
voltage and
date of
manufacture)
12.5 μ F
BRN 2
RED 2
12.5 μ F
1-27
BLACK
GREEN
WHITE
LOWER
SWITCH
RED
LOWER
SWITCH
ORANGE
UPPER
SWITCH
BLUE
UPPER
SWITCH
1.9.8 Interpretation of Digital Controller Lights
Power light on, heat light cycling, trouble light off, and melt light on:
•
If fryer oil temperature is below 180ºF (82ºC), the lights indicate the unit is operating normally.
•
If the oil temperature is above 180ºF (82ºC) and the heat light continues to cycle as if in the
melt cycle, this may indicate a defective probe circuit or low incoming 12VAC to the controller.
Power light on, heat light on, trouble light off, and melt light off:
•
If the fryer oil temperature is above 180ºF (82ºC) and below the setpoint temperature, the
lights indicate the unit is operating properly.
•
If the oil temperature is above the temperature set on the control knob and the heat light remains lit, this may indicate a defective probe circuit.
Power light on, heat light off, trouble light on, and melt light off:
•
If the fryer oil temperature is below 410ºF (210ºC), the lights indicate one of the following:
a. The probe circuit is defective, or
b. There is a connection problem on pins 2 or 10 on the 15-pin wiring harness.
•
1.10
If the fryer oil temperature is above 410ºF (210ºC), the lights indicate a run-away heating circuit.
Troubleshooting Guides
The troubleshooting guides found in the pages that follow are intended to assist service technicians
in quickly isolating the probable causes of equipment malfunctions by following a logical, step-bystep process.
1-28
1.10.1 Troubleshooting the 24VAC Circuit in Units without Interface Boards
Verify that the
ON/OFF switch
is in the ON
positon.
Is 24VAC
present at the gas
valve?
No
Is 24VAC
present at the ON/OFF
switch?
No
Probable cause
is a failed 24-volt
transformer.
Yes
Is the continuity
of the ON/OFF switch OK
(zero resistance in the ON
position)?
No
Probable cause
is a failed ON/OFF
switch.
No
Probable cause is a
failed thermostat.
Yes
Yes
Verify that the temperature
of the cooking oil/
shortening is at least 15
degrees below the
thermostat setting.
Is continuity of
the thermostat OK (zero
resistance)?
Problem is with the gas valve.
Refer to Troubleshooting the Gas
Valve on Page 1-33.
Yes
1-29
1.10.2 Troubleshooting the 24 VAC Circuit in Units with Interface Boards
Verify that the drain
valve is fully closed, then
turn the controller on.
Which LEDs are lit?
None
GV LED (with
or without
other LEDs)
24V LED only
Is 24VAC
present on IFB 24V
terminals?
Yes
No
Probable cause
is a failed 24-volt
transformer.
Probable cause
is a failed interface
board.
No
Is 24VAC
present on J1
Pin 6?
Yes
Attempt to light pilot. If
the pilot will not light, see
Troubleshooting the Gas
Valve on Page 1-33.
No
Is pilot lit?
Yes
If unit has a drain safety switch,
probable cause is open or failed
switch. If not, probable cause is loose
or missing jumper between Pins 10
and 19 of 20-pin terminal block.
No
Is 24VAC
present on Pin 20 of 20-pin
terminal block?
Yes
Probable cause is failed
wiring between 20-pin
terminal block and gas
valve.
No
Is 24VAC
present at the gas
valve?
1-30
Yes
Problem is with gas valve.
See Troubleshooting the
Gas Valve on Page 1-33.
24V
XFMR
24V
INTERFACE
BOARD
LED 24V
K3
LED GV
J1-6
10
20-PIN
TERMINAL
BLOCK
OPTIONAL
DSS
19
20
NOTE: On units not equipped
with a drain safety switch, a
jumper connects pins 10 and 19.
GAS
VALVE
24 VOLT CIRCUIT
ON UNITS WITH INTERFACE BOARDS
1-31
1.10.3 Troubleshooting the Gas Valve
Verify that gasmain
street valve is open and
fryer gasline cutoff valve
is open.
Verify gas valve is
in ON position.
Is 24VAC
present at the gas
valve?
Problem is in the 24VAC
circuit. See Troubleshooting
the 24VAC Circuit on Pages
1-29 and 1-30.
No
Natural
For which gas is
the fryer
configured?
Propane
Is incoming
gas pressure 6-14"
WC (1.49-3.49
kPa)?
Problem is with
fryer gas supply.
Is incoming
gas pressure 11-14"
WC (2.74-3.49
kPa)?
No
Yes
No
Place the ON/OFF
or POWER switch
in the ON position
and light the pilot.
Yes
Does the pilot
remain lit?
Yes
No
Is output from
the thermopile approximately
400 millivolts?
No
Probable cause is a
failed thermopile.
No
Probable cause
is a failed high-limit
switch.
Yes
Problem is a
failed gas valve.
Yes
Is continuity
of the high-limit switch
zero?
1-32
1.10.4 Troubleshooting the Thermostat
Turn the fryer on and
set the thermostat
control knob to the
maximum setting.
Does the
burner light?
Is the
thermostat properly
calibrated?
Yes
No
No
Probable cause is
a failed gas valve.
Yes
Is 24VAC
present at the gas
valve?
Probable cause is
a failed thermostat.
No
While it is still hot, inspect the thermostat
body for damage. Inspect leads for fraying,
burning, breaks, and/or kinks. Replace
thermostat if it is bent, dented, or cracked,
or if leads are damaged.
Allow the cooking
oil/shortening to
cool to at least 15
degrees below the
thermostat setting.
Remove the leads
from the terminal
block and check
continuity.
Thermostat has
failed.
No
Is continuity
OK (resistance is
zero)?
Yes
Replace the leads
in the terminal
block.
Probable cause
is a break or short
in the wiring.
No
Is resistance
of wire from terminal
block to gas valve
zero?
Yes
1-33
Thermostat and
associated wiring
are OK.
Yes
Thermostat is OK.
1.10.5 Troubleshooting the Temperature Probe
While it is still in the frypot,
inspect the probe body for
damage. Inspect the leads
for fraying, burning, breaks,
and/or kinks. If probe is
bent, dented, or cracked, or
if the leads are damaged,
replace the probe.
Determine the temperature of
cooking oil/shortening using a
thermometer or pyrometer
placed at the tip of the probe.
Disconnect the 15-pin harness
from the controller. Measure
probe resistance using J2
Pins 13 and 14.
Is resistance
approximately equal to that
given in the probe resistance chart
for the corresponding
temperature?
Yes
No
Measure resistance
through J2 Pin 13
and ground and J2
Pin 14 and ground.
Is resistance of
each pin 5 megaohms
or greater.
Yes
Probe is OK.
1-34
No
Probe has failed.
Probe Resistance Chart
For use with 45 Series fryers manufactured with Minco Thermistor probes only.
F
60
65
70
75
80
85
90
95
100
105
110
115
120
125
OHMS
1061
1070
1080
1091
1101
1112
1122
1133
1143
1154
1164
1174
1185
1195
C
16
18
21
24
27
29
32
35
38
41
43
46
49
52
F
130
135
140
145
150
155
160
165
170
175
180
185
190
195
OHMS
1206
1216
1226
1237
1247
1258
1268
1278
1289
1299
1309
1320
1330
1340
C
54
57
60
63
66
68
71
74
77
79
82
85
88
91
F
200
205
210
215
220
225
230
235
240
245
250
255
260
265
OHMS
1350
1361
1371
1381
1391
1402
1412
1422
1432
1442
1453
1463
1473
1483
1-35
C
93
96
99
102
104
107
110
113
116
118
121
124
127
129
F
270
275
280
285
290
295
300
305
310
315
320
325
330
335
OHMS
1493
1503
1514
1524
1534
1544
1554
1564
1574
1584
1594
1604
1614
1624
C
132
135
138
141
143
146
149
152
154
157
160
163
166
168
F
340
345
350
355
360
365
370
375
380
385
390
395
400
405
OHMS
1634
1644
1654
1664
1674
1684
1694
1704
1714
1724
1734
1744
1754
1764
C
171
174
177
179
182
185
188
191
193
196
199
202
204
207
1-36
RIGHT
MICROSWITCH
RIGHT
BASKET LIFT MOTOR
COMPUTER
BASKET LIFT RELAY
6 PIN CONNECTOR
INTERFACE BOARD
FOR COMPUTER OR
BASKET LIFT TIMER
ONLY.
SOUND DEVICE
DISCONNECT PLUG
LEFT
MICROSWITCH
LEFT
BASKET LIFT MOTOR
N TO FILTER
BASKET LIFT TIMER
BASKET LIFT RELAY
N TO NEXT FRYER
POWER SUPPLY WITHOUT
BASKET LIFT.
GAS VALVE RELAY
DIGITAL CONTROLLER
PROBE
CAPACITOR
PILOT GENERATOR
HI-LIMIT T'STAT
SAFETY DRAIN OPTION (SEE INSERT)
OPTIONAL PRESSURE SWITCH
INSERT
SOUND DEVICE
(FOR CONTROLLERS ONLY)
8050382E
NOTE:
(1) CONNECT WIRE 21C FROM PIN 1 (20 PIN TERMINAL
BLOCK) DIRECT TO POWER SUPPLY.
(2) CONNECT WIRE 22C FROM PIN 5 (20 PIN TERMINAL
BLOCK) DIRECT TO POWER SUPPLY.
PLAN WIRING DIAGRAM
240/24V, 120/24V, 60HZ, 1Ø, 3 WIRE SERVICE
ANALOG CONTROLLER
H TO FILTER
OPTIONAL BASKET LIFT FOR 45 SERIES ONLY
H TO NEXT FRYER
1.11
Wiring Diagrams
1-37
INTERFACE BOARD
SOUND DEVICE
FOR COMPUTER OR
BASKET LIFT TIMER
ONLY.
COMPUTER
ANALOG CONTROLLER
GAS VALVE RELAY
BASKET LIFT TIMER
TO FILTER TERMINAL BLOCK
TO FILTER TERMINAL BLOCK
OPTIONAL BASKET LIFT FOR 45 SERIES ONLY
PROBE
CAPACITOR
THERMOCOUPLE
DIGITAL CONTROLLER
GAS VALVE
HI-LIMIT T'STAT
PLAN WIRING DIAGRAM
CE 230V MJ45 W/COMPUTER AND BASKET LIFT
INSET
8050535B
SOUND DEVICE
(FOR CONTROLLERS ONLY)
1-38
TO FILTER
TO FILTER
TO BASKET LIFT (OPTIONAL)
POWER
MELT CYCLE SWITCH/LIGHT
ON/OFF SWITCH
SOUND DEVICE
SAFETY DRAIN OPTION
HEATING LIGHT
TO NEXT FRYER
TERMINAL BLOCK
TO NEXT FRYER
TERMINAL BLOCK
THERMOCOUPLE
SCREENED AREA FOR MELT CYCLE OPERATION
DISCONNECT PLUG
GAS VALVE
OPERATING
THERMOSTAT
8050534D
CAPACITOR
GAS VALVE
HIGH LIMIT THERMOSTAT
HIGH LIMIT
THERMOSTAT
THERMOCOUPLE
OPERATING THERMOSTAT
ON/OFF SWITCH
MELT CYCLE TIMER
HEATING LIGHT
MELT CYCLE SWITCH/LIGHT
PLAN WIRING DIAGRAM
CE FM/MJ 45 W/0 COMPUTER
SEE INSET A-A
FOR 50-2
FILTER PUMP MOTOR
ON/OFF SWITCH
1 ST. FRYER - RIGHT OF FILTER
PLAN WIRING DIAGRAM FOR FILTER MAGIC II
(DIRECT)
TO FRYER POWER SUPPLY
FOR (DIRECT) UNITS
INSET A-A
PUMP
RELAY
INSET B-B
PUMP
HEATER
1 ST. FRYER - LEFT OF FILTER
FILTER PUMP MOTOR
ON/OFF SWITCH
REPEAT SAME CIRCUIT ON NEXT FRYER IF NEEDED
SEE INSET B-B
FOR 50-2
1-39
8050385D
REPEAT SAME CIRCUIT ON NEXT FRYER IF NEEDED
PLAN WIRING DIAGRAM
45 SERIES BASKET LIFT SYSTEM
LEFT
BASKET LIFT MOTOR
LEFT
MICROSWITCH
RIGHT
BASKET LIFT MOTOR
RIGHT
MICROSWITCH
DISCONNECT PLUG
MILLIVOLT FRYER WIRING
6 PIN CONNECTOR
TO 120V OR 240V
TRANSFORMER IN
FRYER
6 PIN CONNECTOR
DISCONNECT PLUG
LEFT TIMER
RIGHT TIMER
8050379E
1-40
PLAN WIRING DIAGRAM
45 SERIES BASKET LIFT SYSTEM
LEFT
BASKET LIFT MOTOR
LEFT
MICROSWITCH
RIGHT
BASKET LIFT MOTOR
RIGHT
MICROSWITCH
DISCONNECT PLUG
MILLIVOLT FRYER WIRING
6 PIN CONNECTOR
TO 120V OR 240V
TRANSFORMER IN
FRYER
6 PIN CONNECTOR
DISCONNECT PLUG
LEFT TIMER
RIGHT TIMER
8050379E
1-41
THIS PAGE INTENTIONALLY LEFT BLANK.
45 SERIES GAS FRYERS SERVICE AND PARTS MANUAL
CHAPTER 2: PARTS LIST
ACCESSORIES
1
4
3
2
5
6
7
14
8
9
10
11
12
13
ITEM
1
2
3
*
*
4
*
5
6
7
8
9
10
11
12
PART #
803-0271
803-0099
803-0132
803-0136
803-0103
806-5518
826-0993SP
823-1885
910-4617
910-2285
910-7515
910-7443
910-7515SP
910-2572
806-1698SP
806-1699
13
810-0074
14
810-0073
* Not illustrated.
COMPONENT
Basket, Twin
Basket, Full (cannot be used with basket lifts)
Basket Support Rack
Basket Support Screen (screen w/handle used in place of Item 3)
Sediment Tray
Cover, Frypot or Holding Station
Handle Kit, Frypot Cover (includes handle and screws)
Connecting Strip w/back plate (Burger King only)
Connecting Strip (blunt point, ½” sides, 20.70” long)
Connecting Strip (blunt point, 1” sides, 20.80” long)
Connecting Strip (sharp point, ½” sides, 21.73” long)
Connecting Strip (sharp point, 1” sides, 21.73” long)
Connecting Strip (sharp point, 1” sides, 21.84” long)
Connecting Strip (sharp point, 3” sides, 21.84” long)
Gas Line, 1-Inch Dormont Flexible (includes Items 13 and 14)
36-Inch (for gas line only (w/o Items 13 and 14), use 810-0088)
42-Inch (for gas line only (w/o Items 13 and 14), use 810-0085)
Quick-Disconnect Fitting, 1-Inch Male
Quick-Disconnect Fitting, 1-Inch Female
2-1
6
36
1
23
9
5
11
12
5
27
37
2-2
20
28
30
29
33
24
22
24
17
14
31
32
35
15
16
25
7
16
19
15
13
17
21
23
2
4
11
18
10
3
26
34
BASKET LIFT ASSEMBLIES AND COMPONENT PARTS
Bell Crank Basket Lift
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
PART #
807-0107
807-0108
807-0124
807-0240
826-1680
826-1358
809-0050
809-0063
809-0076
809-0082
809-0097
809-0113
809-0127
826-1370
809-0155
809-0196
826-1381
809-0360
826-1374
809-0480
810-0045
810-0052
810-0170
810-0172
810-0192
810-0220
812-0138
813-0035
823-1419
900-4110
910-0119
910-3177
910-3783
910-9361
920-3233
920-6076
823-06931
823-06932
COMPONENT
Gear Motor, Basket Lift
120VAC
240VAC
Bushing, Plastic
Microswitch
Clamp, Plastic Wire (Pkg. of 8)
Nut, 6-32 Hex (Pkg. of 25)
Nut, 2-32 Hex
Nut, Jam ⅜-16 Hex
Nut, ¼-20 x ¾ Expansion
Ring, Truarc Retaining
Screw, 6-32 X 1-inch Slotted Truss Head
Screw, 2-32 X 1½-inch Slotted Truss Head
Screw, ¼-20 X ½-inch Slotted Round Head
Screw, ¼-20 X 1¼-inch Slotted Round Head (Pkg. of 10)
Leveling Screw
Washer, ⅜-inch Steel Flat
Washer, Nylon (Package of 10 each 809-0203)
Screw, 2-32 X ⅜-inch Slotted Hex Washer Head
Screw, 10 X ½-inch Hex Washer Head (Pkg. of 25)
5
Setscrew, ¼-28 X ⁄8-inch Hex Socket Head
Bushing, Plastic
Bellcrank and Cam
Pin, Connecting
5
Plug, ⁄8-inch Hole S/S
Rod, Basket Lift
Spacer, Tubular
Insulation, Paper (Fishpaper)
Bushing, Bronze
Box, Electrical Wiring
Angle, Bearing Support
Cover, Electrical Wiring Box
Panel, Stainless Steel Rear Access (for mild steel, use 900-3177)
Cover, Stainless Steel Rear Cabinet (for mild steel, use 900-3783)
Housing, Basket Lift Stainless Steel (for mild steel, use 900-9361
Plate, Basket Lift Motor Mounting
Link, Basket Lift
Basket Lift Arm, Left
Basket Lift Arm, Right
NOTE: See Page 2-20 for Roller Bracket Assembly.
2-3
9
6
19
15
2-4
23
(After 10/02)
5
208-250V Configuration
1
14
100-120V Configuration
2
26
7
5
10
14
13
12
21
20
(Before 11/02)
11
5
3
8
13
16
14
17
4
22
12
18
24
14
NOTES:
1. Assemblies 106-1807SP (100-120V) and 106-1810SP (208-250V) do not
include Items 8, 16, 24, 25, and 26. These items must be ordered separately.
2. For 100-120V units, each individual resistor (807-2661) may be replaced or
the entire reistor assembly (806-8530SP) may be replaced.
3. For 208-250V units, the entire resistor assembly (106-2771 or 806-9185) must
be replaced.
4. Wiring has been omitted for clarity.
10
25
Modular Basket Lift
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
PART #
200-2942
900-7655
806-5964SP
807-2133
807-2572
806-8530SP
106-2771
809-0082
826-1361
809-0127
809-0186
826-1366
809-0247
826-1359
826-1371
826-1374
809-0503
810-0172
810-1012
812-0442
813-0035
816-0033
900-5529
901-8499
902-8499
910-4776
823-06931
823-06932
COMPONENT
Mount, Modular Basket Lift**
For use on units with 12-pin connectors
For use on units with 6-pin connectors
Motor Assembly, Modular Basket Lift***
Capacitor, 12.5 µFarad, 250VAC Motor Run
Microswitch
Resistor Assembly
100-120V Modular Basket Lift (see Note 2 in illustration)
208-250V Modular Basket Lift (before 11/02 use 806-9185; see illust. Note 3)
Ring, Truarc Retaining
Screw, 2-32 X 1-inch Slotted Truss Head (Pkg. of 25)
Screw, ¼-20 X ½-inch Slotted Round Head
Lock Washer w/External Teeth, #8
Nut, 4-40 Hex Keps (Pkg. of 25)
Nut, 2-32 Hex Keps
Screw, 4-40 X ¾-inch Slotted Round Head (Pkg. of 25)
Screw, #8 X ½-inch Hex Head Drill Point (Pkg. of 25)
Screw, #10 X ½-inch Hex Head (Pkg. of 25)
Screw, 2-32 X ½-inch Hex Head
5
Plug, ⁄8-inch Stainless Steel Hole
Rod, Modular Basket Lift
Insulation, Microswitch
Bushing, Bronze, .640” ID
Tie Wrap, Screw Mount
Gusset, Modular Basket Lift Motor
Chassis, Modular Basket Lift, Left
Chassis, Modular Basket Lift, Right
Cover, S/S Modular Basket Lift (for CRS cover use 900-4776)
Arm, Left Basket Lift
Arm, Right Basket Lift
Basket Lift Assemblies (see Note 1 in illustration)
100-120V w/o Relay
208-250V w/o Relay
*
106-1807SP
*
106-1810SP
*** Not illustrated.
*** Basket lift assemblies manufactured prior to February 2002 have 6-pin connectors; those manufactured
February 2002 and later have 12-pin connectors. Verify the connector in use before ordering wiring
assemblies or mounts.
*** To replace stripped drive gear only, order 810-1013 (gear), 810-0973 (Woodruff key) and 809-0504
(setscrew).
NOTE: See Page 2-20 for Roller Bracket Assembly.
2-5
BURNER ASSEMBLY COMPONENT PARTS
9
10
1
4
3
11
5
8
6
NOTE: Red dot indicates Propane/Butane Pilot
Assembly; green dot indicates Manufactured
Gas; no dot indicates Natural Gas.
Robertshaw gas valves (illustrated above)
are no longer available. Order kit
826-1596 to replace natural gas valves,
826-1597 to replace propane gas valves, or
826-1643 to replace manufactured gas valves.
5
7
Gas Valve Conversion Kits:
Non-CE Natural to Propane: 826-1143
Non-CE Propane to Natural: 826-1144
2
CE Natural to Propane: 826-1200
CE Propane to Natural: 826-1201
2-6
ITEM
1
2
3
4
PART #
806-0225SP
826-1155
807-1906
810-1001
823-0496
810-0407
826-1357
826-1386
810-0361
810-0131
812-1301
810-0343
826-1387
810-0952
810-0339
812-0914
812-1302
812-0444
5
6
7
810-1830
806-8688SP
810-0426
810-0616
810-1773
806-8689SP
810-0427
810-0683
823-0574
810-1873
826-1527
812-1284
8
9
10
*
810-0705
812-0278
810-0691
810-0975
807-3294
807-3295
807-3354
810-0353
11
806-6710SP
806-6711SP
* Not illustrated.
COMPONENT
Deflector (Target) Assembly (use 814-0034 for ceramic only)
Ignitor Kit, Optional Piezo
Electrode Assembly
Trigger
Manifold, Burner
Orifice
Manufactured Gas, 2.15mm (0-1999 Ft)
Natural Gas
1.45mm (0-1999 Ft) (Pkg of 10)
1.40mm (2000-3999 Ft) (Pkg of 10)
1.36mm (4000-5999 Ft)
1.30mm (6000-7999 Ft)
1.27mm (8000-8999 Ft)
1.25mm (9000-10,000 Ft)
Propane/Butane Gas
0.86mm (0-1999 Ft) (Pkg of 10)
0.82mm (2000-3999 Ft)
0.81mm (4000-5999 Ft)
0.78mm (6000-7999 Ft)
0.76mm (8000-8999 Ft)
0.74mm (9000-10,000 Ft)
Pilot Assembly
Natural Gas, w/Thermopile (non-CE w/twin-leads)
Natural Gas, w/Thermocouple (CE w/co-axial lead)
Natural Gas, w/o Thermopile or Thermocouple
Propane or Butane Gas, w/Thermopile (non-CE w/co-axial lead)
Propane or Butane Gas, w/Thermopile (non-CE w/twin leads)
Propane or Butane Gas, w/Thermocouple (CE)
Propane or Butane Gas, w/o Thermopile or Thermocouple)
Manufactured Gas, w/Thermocouple (CE and non-CE)
Shield Assembly, Burner Heat
Thermopile/Thermocouple
Thermopile w/push-on terminals (used in non-CE Pilot Assemblies)
Kit, Thermocouple with adapter (used in CE Pilot Assemblies)
Thermocouple w/threaded terminal (component of 826-1527)
Tube, Pilot Gas
For use with all burner assemblies except Hong Kong export units
For use with Hong Kong export units only
Tube, Vent
Valve, Gas (Non-CE) (see Note 1 below)
Knob, Gas Valve
Natural Gas (for 240V, use 807-0025)
Propane/Butane Gas (for 240V, use 807-0759)
Manufactured Gas (other than Hong Kong export units)
Manufactured Gas (Hong Kong export units only)
Valve, Gas (CE)
Natural Gas (see Note 2 below)
Propane Gas (see Note 2 below)
NOTES: 1. A gas valve capacitor (P/N 806-4781) is required on gas valves used on units with
Thermostat Controllers. 2. An adapter kit (P/N 812-1256SP) is required to connect the high-limit
thermostat to Item 11. See Page 2-34 for details.
2-7
CABINET ASSEMBLIES AND COMPONENT PARTS
MJ145, F145 (Filter Ready), and Spreader Cabinet Assembly Components
5
7
3
4
2
2
6
1
8
Spreader Cabinet
(Typical)
1
Fryer Cabinet
(Typical)
See Page 2-9 for
access opening covers.
9
9
NOTES: Fryer and spreader cabinet assemblies are identical except for the backs — spreader
backs do not have a formed edge at the top. Cabinet sides with access openings are used on
F145 units or on spreader cabinets placed in batteries of fryers equipped with built-in filtration
systems.
NOTE: See Page 2-14 for casters, legs, and associated hardware, and Page 2-10 for holding station
pan components.
ITEM
1
2
3
PART #
900-2568SP
900-4813SP
910-7213SP
900-7213SP
4
910-6983SP
900-6983SP
5
911-9323SP
901-9323SP
6
912-9323SP
902-9323SP
7
911-9324SP
901-9324SP
8
9
912-9324SP
902-9324SP
826-1374
COMPONENT
Base, Cabinet, One-Piece
Brace, Cabinet Top
Back, Spreader Cabinet
Stainless Steel
Aluminized Steel
Back, Fryer Cabinet
Stainless Steel
Aluminized Steel
Side, Left Cabinet w/o Access Openings
Stainless Steel
Enameled
Side, Right Cabinet w/o Access Openings
Stainless Steel
Enameled
Side, Left Cabinet w/Access Openings
Stainless Steel
Enameled
Side, Right Cabinet w/Access Openings
Stainless Steel
Enameled
Screw, #10 X ½-inch Hex Washer Head (package of 25)
2-8
MJ45 Batteries
8
9
6
4
10
7
3
1
2
5
(MJ345 ILLUSTRATED IS TYPICAL OF ALL)
NOTE: See Page 2-14 for casters, legs and associated hardware.
ITEM
1
2
3
4
5
6
PART #
900-4426SP
900-2395SP
900-2396SP
900-9373
900-6979SP
900-7730SP
900-9430SP
900-9318
806-5209SP
911-9323SP
901-9323SP
7
912-9323SP
902-9323SP
8
9
10
910-6983SP
900-6983SP
900-7326
826-1374
COMPONENT
Channel, Left and Right Side
Channel, Front and Rear
Double
Triple
Quad
Post, Door
Brace, Cabinet Top
Double
Triple
Quad
Leg Pad Assembly
Side, Left Cabinet
Stainless Steel (use 911-9324SP for side with access openings)
Enameled (use 901-9324SP for side with access openings)
Side, Right Cabinet
Stainless Steel (use 912-9324SP for side with access openings)
Enameled (use 902-9324SP for side with access openings)
Back, Cabinet
Stainless Steel
Aluminized Steel
Divider, Cabinet
Screw, #10 X ½-inch Hex Washer Head (package of 25)
2-9
FM45 Batteries with Built-In Filtration
1
NOTE: Items 1-15 are used in
all FM45 Builit-In Filter
configurations and therefore
are not repeated for the FM245
and FM145 (Filter on Right)
illustrations.
2
4
3
15
7
6
5
22
9
10
28
11
FM145 (FILTER ON LEFT)
(All components except Items 27 and
28 are the same for FM245 and FM345
units with the filter on the left.)
20
12
13
16
17
26
18
22
14
25
8
27
29
(See Page 2-9 for Leg Pad Assembly)
25
24
29
28
FM245 (FILTER BETWEEN FRYERS)
(All components except Items 27 and 28
are the same for FM345 cabinets with
the filter between fryers.)
27
26
19
26
25
20
27
28
25
24
29
FM145 (FILTER ON RIGHT)
(All components except Items 27 and 28
are the same for FM245 and FM345
units with the filter on the right.)
27
19
23
21
26
16
17
2-10
ITEM
1
2
3
4
5
6
PART #
910-7480
806-8274SP
900-7277
910-7274SP
900-7274SP
900-4089
910-6983SP
900-6983SP
7
911-9323SP
901-9323SP
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
912-9323SP
902-9323SP
900-7414
900-6979SP
809-0413
900-4391SP
826-1379
900-1700
900-7314SP
910-1601
900-1621
901-1599
901-1595
902-1599
902-1595
901-4390
902-4390
806-4917
900-4426
900-4383
900-2394
900-2395
900-2396
28
29
900-1631
900-7243
900-9319
900-1630
900-7244
900-9322
900-7242
900-9321
900-9320
826-1374
COMPONENT
Trim, Filter Cabinet Top
Pan Assembly, Filter/Spreader Cabinet
Support, Drain Pan
Back w/Access Opening, Filter Cabinet
Stainless Steel
Aluminized Steel
Cover, Cabinet Back Access
Back, Cabinet
Stainless Steel
Aluminized Steel
Side, Left Cabinet
Stainless Steel
Enameled
Side, Right Cabinet
Stainless Steel
Enameled
Shield, Filter Magic Pan
Post, Door
Spacer, .25 x .160 8 Gauge Nylon (located behind Item 10 at bottom)
Brace, Front Cabinet
Screw, #10 x ½-inch Philips Truss Head (package of 10)
Bracket, Drain Support
Divider, Cabinet
Leg, Filter
Plate, Rail Mount (located inside front edge of Item 7)
Bracket, Left Pan Rail (used on cabinets with filter on left)
Bracket, Left Pan Rail (used on cabinets with filter on right or in middle)
Bracket, Right Pan Rail (used on cabinets with filter in middle)
Bracket, Right Pan Rail (used on cabinets with filter on right)
Channel, Left Filter Side
Channel, Right Filter Side
Rail Assembly, Filter Magic
Channel, Fryer Outside
Channel, Fryer Inside
Channel, Fryer Front
Single Fryer
Double Fryer
Triple Fryer
Channel, Filter Magic Cabinet Rear
FM145 Filter Left
FM245 Filter Left
FM345 Filter Left
FM145 Filter Right
FM245 Filter Right
FM345 Filter Right
FM245 Filter Middle
FM345 (Fryer, Fryer, Filter, Fryer)
FM345 (Fryer, Filter, Fryer, Fryer)
Screw, #10 X ½-inch Hex Washer Head (package of 25)
2-11
Filter Magic II Add-On Cabinet Components
31
30
3
29
4
29
2
18
9
1
25
24
20
23
10
22
19
15
14
16
12
17
21
13
14
25
26
27
ADD-ON
FILTER MAGIC CABINET
18
28
18
8
7
6
5
20
11
22
15
14
16
12
17
21
13
18
UNDERCOUNTER ADD-ON
FILTER MAGIC CABINET
14
2-12
ITEM
1
PART #
911-9324SP
901-9324SP
2
912-9324SP
902-9324SP
3
910-7274SP
900-7274SP
4
910-4089
900-4089
5
911-7677SP
901-7677SP
6
912-7677SP
902-7677SP
7
8
9
10
11
12
13
14
15
16
17
18
19
20
910-4786
900-4786
910-7680
900-4813SP
900-4391SP
900-4785
806-5317SP
806-4897SP
900-1621
910-1601
810-0007
910-1832
826-1374
826-1379
910-0889
900-0889
21
22
23
24
25
26
27
28
29
30
31
910-0890
900-0890
809-0359
900-7414
900-4175
826-1362
809-0429
809-0191
810-0665
900-7277
806-8274SP
910-7480
COMPONENT
Side, Left Cabinet, w/Access Openings
Stainless Steel
Enameled
Side, Right Cabinet, w/Access Openings
Stainless Steel
Enameled
Back w/Access Opening, Filter Cabinet
Stainless Steel
Aluminized Steel
Cover, Cabinet Back Access
Stainless Steel
Aluminized Steel
Side, Left Undercounter Cabinet
Stainless Steel
Enameled
Side, Right Undercounter Cabinet
Stainless Steel
Enameled
Back, Undercounter Cabinet
Stainless Steel
Aluminized Steel
Cover, Undercounter Cabinet
Brace, Cabinet Top
Brace, Cabinet Front
Brace, Undercounter Cabinet Top and Center
Rail Assembly
Base Assembly (includes leg pad assembly 806-5209 (see Page 2-13))
Plate, Rail Mount (located inside lower front edge of Items 1, 2, 5, and 6)
Leg, Filter Cabinet (use 910-8673 on units with rear casters)
Leg, Adjustable
Retainer, Leg Insert, Full Height
Screw, #10 X ½-inch Hex Washer Head (Pkg. of 25)
Screw, #10 X ½-inch Philips Truss Head (Pkg. of 10)
Cover, 4-inch X 4-inch Access Opening
Stainless Steel
Enameled
Cover, 4-inch X 4-inch Access Opening
Stainless Steel
Enameled
Screw, #8 X ¼-inch Hex Washer Head (for access covers)
Shield, FM Pan
Mount, Motor
Nut, ¼-20 Hex (Pkg. of 10)
Bolt, ¼-20 X 2-inch Hex Head
Washer, ¼-inch Lock
Nut, ¼-20 Hex Leveling
Support, Holding Station Pan
Pan Assembly, Holding Station
Trim, Holding Station
2-13
CASTERS, LEGS, AND ASSOCIATED HARDWARE
1
6
ITEM
PART #
1
823-2669
2
826-1130
3
826-1118
4
826-1117
5
826-1138
6
826-1237
7
826-1115
8
826-1095
9
826-0900
*
826-1113
*
826-1098
*
826-1043
* Not illustrated.
3
2
7
5
2
8
9
COMPONENT
Caster, 3” Swivel w/Brake (optional substitute for front leg in FM add-on cabinet)
Caster, 3” Swivel w/Brake (810-0651 and mounting hardware)
Caster, 5” Swivel w/Brake (810-0357 and mounting hardware)
Caster, 5” Swivel w/o Brake (810-0356 and mounting hardware)
Caster, 5” Rigid w/o Brake (810-0378 and mounting hardware)
Leg Assembly, Stainless Steel
Leg Assembly, Nickel Plated
Anchor Strap Kit (for use on single fryers w/legs)
Chain Restraint Kit (for use on fryers w/casters)
Kit, Mounting Hardware, 1 Caster/Leg (4 mounting bolts and lock washers)
Kit, Mounting Hardware, 2 Casters/Legs (8 mounting bolts and lock washers)
Kit, Mounting Hardware, 4 Casters/Legs (16 mounting bolts and lock washers)
NOTE: Items 2 through 8 include 1 caster or leg, 4 mounting bolts, and 4 lock washers.
2-14
COMPONENT SHIELDS, FILTER BOX ASSEMBLIES, AND COMPONENT PARTS
4
6
7
8
2
4
2
6
7
3
8
17
3
18
20
21
9
11
9
3
13
12
3
3
14
15
16
10
5
5
1
1
Non-CE Shields
CE Shield
19
20
21
Component Shield Assemblies with Interface Boards
ITEM
PART #
806-4773SP
806-4775SP
806-6629SP
1
2
3
4
5
*
6
7
8
9
10
11
12
900-4340
824-0161
809-0360
806-3548
806-7505
807-1582
810-2243
809-0349
809-0096
809-0250
807-2469
810-0045
807-0855
807-0979
807-0800
807-0680
13
807-1999
14
807-0066
15
809-0097
16
826-1358
17
816-0217
18
810-1164
19
810-1168
20
826-1359
21
826-1366
* Not illustrated.
COMPONENT
Complete Shield Assemblies
100-120V, 50/60 Hz (Non-CE)
208-240V, 50/60 Hz (Non-CE)
230V, 50 Hz (CE)
Components
Shield, Component
Support, Interface Board
Screw, #8 X ⅜-inch Washer Slotted Hex Head
Interface Board
Non-CE Universal Replacement
CE Universal Replacement
Relay, 12VDC
Clip, Relay Retaining
Spacer, 4 x 6 mm, Interface Board Standoff
Screw, 6-32 X ⅝-inch Slot Head
Nut, 6-32 Hex Keps
Bushing, Heyco (fits ⅞-inch (.875-inch) hole)
Bushing, Heyco (fits 1.25-inch hole)
Transformer, 12V Secondary
100-120V 50/60 Hz Primary
208-240V 50/60 Hz Primary
Transformer, 24V Secondary
100-120V 50/60 Hz Primary
208-240V 50/60 Hz Primary
Transformer, 208-240V Primary/12V and 24V Secondary Dual Voltage
Terminal Block, 20-Position
Screw, 6-32 X 1-inch Slotted Round Head
Nut, 6-32 Hex (Pkg. of 25)
Paper, Insulating
Terminal Block, 6-Position
Terminal Block, 8-Position
Screw, 4-40 X ¾-inch Slotted Round Head (Pkg. of 25)
Nut, 4-40 Hex Keps (Pkg. of 25)
2-15
19
17
13
18
10
14
13
2
20
3
4
1
100-120V Non CE
Electromechanical timer shown for
identification purposes only. This
timer has been replaced by Items
17, 18, and 19 (shown in the 100120V illustration) in all applications.
13
16
14
11
13
20
2
3
4
1
208-240V Non-CE
NOTE: Melt cycle timers (Items
16 and 17) are not present in
shield assemblies 806-4774SP,
806-4776SP, and 806-6630SP.
19
17
13
18
14
12
13
15
20
7
5
6
8
9
208-240V CE
Component Shield Assemblies without Interface Boards
2-16
8
1
9
ITEM
PART #
806-4774SP
806-4776SP
806-4772SP
806-4777SP
806-6630SP
806-6632SP
1
2
3
4
5
6
7
8
9
10
11
900-4340
807-0066
809-0097
826-1358
816-0217
810-1164
810-1168
826-1359
826-1366
807-0800
807-0680
807-2180
*
807-1597
12
807-1999
13
826-1374
14
810-0045
15
807-2469
16
826-1546
17
806-9613
18
900-8741
19
809-0580
20
807-0156
* Not illustrated.
COMPONENT
Complete Shield Assemblies
120V, 50/60 Hz without Melt Cycle Timer (Non-CE)
240V, 50/60 Hz without Melt Cycle Timer (Non-CE)
120V, 50/60 Hz with Melt Cycle Timer (Non-CE)
240V, 50/60 Hz with Melt Cycle Timer (Non-CE)
230V, 50 Hz without Melt Cycle Timer (CE)
230V, 50 Hz with Melt Cycle Timer (CE)
Components
Shield, Component
Block, Terminal, 20-Pin
Screw, 6-32 x 1-inch Slotted Truss Head
Nut, 6-32 Hex (Pkg. of 25)
Paper, Insulating
Terminal Block, 6-Position
Terminal Block, 8-Position
Screw, 4-40 X ¾-inch Slotted Round Head (Pkg. of 25)
Nut, 4-40 Hex Keps (Pkg. of 25)
Transformer, 100-120V Primary/24V Secondary 50/60 Hz 50VA
Transformer, 208-240V Primary/24V Secondary 50/60 Hz
20VA without fuse
50 VA with fuse
Fuse, 3-Amp Slow-Blow (for use w/transformer 807-2180)
Transformer, 208-240V Primary/12V and 24V Secondary Dual Voltage
Screw, #10 x ½-inch Hex Washer Head (Pkg of 25)
Bushing, Heyco (fits 1.25-inch hole)
Bushing, Heyco (fits ⅞-inch (.875-inch) hole)
Kit, Melt Cycle Timer (Items 17, 18, and 19) replaces electromechanical timer
PC Board Assembly, Melt Cycle Timer (50 and 60 Hz)
Bracket, Melt Cycle Timer
Standoff, PC Board
Plug, 9-Pin
2-17
Filter Boxes
3
13
16
17
or
14
16
4
5
2
17
1
19
19
3
4
5
6
7
17
13
18
7
14
17
18
17
or
Non-CE Standard
6
16
15
16
16
17
17
19
CE Standard
3
8
9
11
PART #
806-4359SP
806-4360SP
806-6709SP
806-4361SP
806-4362SP
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
200-0409
200-0410
807-0012
809-0096
826-1358
807-0276
809-0097
816-0217
810-1164
810-1168
826-1359
826-1366
807-0800
807-0680
807-1999
809-0103
809-0050
807-0124
809-0360
4
5
12
18
ITEM
Non-CE
Undercounter
10
11
12
COMPONENT
Complete Box Assembly
100-120V Standard Cabinet
208-240V Standard Cabinet (Non-CE)
230V Standard Cabinet (CE)
100-120V Undercounter Cabinet
208-240V Undercounter Cabinet (Non-CE)
Components
Box, Standard Filter Control
Box, Undercounter Filter Control
Relay, 15 Amp, SPST, Filter
Screw, 6-32 X ⅝-inch Slot Head
Nut, 6-32 Hex (Pkg. of 25)
Terminal Block, 20-Position
Screw, 6-32 X 1-inch Slotted Round Head
Paper, Insulating
Terminal Block, 6-Position
Terminal Block, 8- Position
Screw, 4-40 X ¾-inch Slotted Round Head (Pkg. of 25)
Nut, 4-40 Hex Keps (Pkg. of 25)
Transformer, 100-120V Primary/24V Secondary 50/60 Hz 50VA
Transformer, 208-240V Primary/24V Secondary 50/60 Hz 20VA
Transformer, 208-240V Primary/12V & 24V Secondary Dual Voltage (CE)
Screw, 8-32 X ½-inch Slotted Truss Head
Nut, 8-32 Hex
Bushing, Heyco (fits ⅞-inch (.875-inch) hole)
Screw, #8 X ⅜-inch Washer Slotted Hex Head
2-18
THIS PAGE INTENTIONALLY LEFT BLANK
2-19
23
26
24
20
14
28
30
29
19
18
9
10
11
12
13
8
21
15
25
7
5
22
16
6
1
5
6
2
17
27
5
6
3
5
6
4
CONTROL PANEL ASSEMBLIES, FLUE CAPS, TOP CAPS, and RELATED ITEMS
2-20
ITEM
1
*
2
3
4
5
6
7
8
9
10
11
12
13
14
PART #
810-1403
809-0921
823-1462
106-2185
809-0171
826-1351
806-9257SP
910-8284
826-1334
809-0190
810-0374
810-0194
809-0047
910-5018
910-6545
823-3749
15
823-2540
823-3536
16
823-2541
823-3537
17
823-2569
18
900-5486
19
900-4253
20
824-0404
21
824-0405
22
824-0406
23
824-0407
24
806-4732SP
25
806-4733SP
26
806-4734SP
27
806-5018SP
28
910-8503
29
910-8505
30
910-3557
*
826-1379
*
826-1371
* Not illustrated.
COMPONENT
Basket Hanger, Wire Form
Spacer, Wire Form Basket Hanger
Basket Hanger, Extruded Aluminum (No longer available; use 810-1403)
Basket Hanger, Burger King
Bracket, Burger King Easy-Off Basket Hanger (used w/Item 1)
Thumbscrew, ¼-20 X 1⅜-inch Basket Hanger
Nut, Cage (receives Basket Hanger Thumbscrew) (pkg of 10)
Roller Assembly, Basket Lift (Complete)
Bracket, One-Piece Roller Guide
Capscrew, ¼ – 20 x 1¼” Stainless Steel Hex Head (pkg of 5)
Washer, ¼” Stainless Steel Flat
Spacer, Tubular
Roller, Basket Lift Guide
Nut, ¼ – 20 Cap (also used w/Item 4)
Flue Cap, Single Fryer, w/lip
Standard
Optional (without lip along flue opening)
Burger King with Button Studs (used w/Item 4)
Flue Cap, 2-Fryer Battery
Standard
Burger King with Button Studs (used w/Item 4)
Flue Cap, 3-Fryer Battery
Standard
Burger King with Button Studs (used w/Item 4)
Flue Cap, 4-Fryer Battery
Support, Flue Cap
Flue Cap Retaining Strip
Top Cap, Single Fryer
Top Cap, Two-Fryer Battery
Top Cap, Three-Fryer Battery
Top Cap, Four-Fryer Battery
Control Panel Assembly, Single Fryer
Control Panel Assembly, 2-Fryer Battery
Control Panel Assembly, 3-Fryer Battery
Control Panel Assembly, 4-Fryer Battery
Panel, FM Standard Cabinet Front
Panel, FM Undercounter Cabinet Front
Flue Deflector
Screw, #10 X ½-inch Philips Head (pkg of 10) (attaches top cap)
Screw, #8 X ½-inch Hex Washer Head (pkg of 25) (attaches flue cap)
2-21
CONTROLLER ASSEMBLIES (Thermostat Controllers)
CONTROLLER WITHOUT TIMERS
26
12
13
2
9
10
11
1
14
CONTROLLER WITH MECHANICAL TIMERS
27
2
17
12
13
6
3
4
1
15
9
10
11
16
17
CONTROLLER WITH ELECTRIC TIMERS
2
NOTE: Thermostat shaft and
associated components are the
same for all configurations.
23
12
7
13
8
24
25
19
18
5
1
11
20
22
21
2-22
10
9
27
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PART #
802-0765
802-1470
802-1473
910-1551
810-0334
810-1287
810-1822
810-1823
807-1525
807-3498
807-3575
826-1395
826-1338
810-0585
826-1552
807-0401
16
950-0246
17
809-0093
18
810-0276
19
810-0999
20
809-0157
21
826-1361
22
809-0050
23
900-2241
24
900-2071
25
826-1371
26
910-4345
27
910-4344
*
802-0336
*
806-4797
* Not illustrated.
COMPONENT
Label, Control Panel
Label, Thermostat Dial
Label, 15-Minute Mechanical Timer Bezel
Bezel, 15-Minute Mechanical Timer
Knob, Operating Thermostat
Knob, 15-minute Mechanical Timer
Knob, 15-Minute Electrical Timer Replacement
Push Button, White 15-Minute Electrical Timer Replacement
Light, White Melt Cycle Indicator, 24V
Switch, Melt Cycle Rocker, 24V
Plug, Blank Switch (used on units without melt cycle option)
Plug, Snap-in Reducer, S/S (Pkg of 10)
Bushing, Plastic, Thermostat Shaft (Pkg of 25)
Timer, 15-minute Mechanical Basket Lift
Timer, 15-Minute Electrical Basket Lift
100-120V
208-240V
Insulation, Double Electric Timer
Screw, 6-32 X 3/16-inch Slotted Flat Head
Adapter, Shaft End
Shaft, Flexible
Set Screw
Stop Screw (Pkg of 25)
Nut, 5-32 Hex
Bracket, Thermostat
Bracket, Thermostat Shaft Guide
Screw, #8 X ½-inch Slotted Hex Washer Head (Pkg. of 25)
Panel, Thermostat Control without Timers
Panel, Thermostat Control with Electric or Mechanical Timers
Label, Frymaster Logo
Alarm, Open Drain (Buzzer)
NOTE: See Pages 2-16 and 2-17 for melt cycle timers.
2-23
CONTROLLER ASSEMBLIES (Other than Thermostat Controllers)
1
2
3
4
SOLID STATE
ITEM
1
2
3
PART #
106-1149SP
106-1199SP
106-1216
106-1218
106-1230
106-2079SP
106-1501
106-1505
4
806-3559
*
910-3690
*
806-3660
*
826-1379
*
826-1032SP
* Not illustrated.
COMPONENT
Computer Magic III
Built-In, Non-CE
Built-In CE
Remote LP03
Remote On-Hood
Remote In-Hood
Controller, Basket Lift Timer
Controller, Digital
Non-CE
CE
Controller, Solid State (controller knob is 810-0387)
Panel, Blank Control (for use on fryers with remote computers)
Sound Device (for use w/all CM III Computers)
Screw, #10 X ½-inch Philips Truss Head (computer screws) (Pkg. of 10)
Kit, Control Panel Screws (2 screws and 2 screw retainers)
2-24
DOOR ASSEMBLY
1
5
4
2
7
3
6
5
ITEM
PART #
806-8320
806-6405SP
1
106-0554SP
2
826-1343
3
810-1422
4
826-1379
5
810-1508
6
824-0616SP
7
900-4807
*
810-1105
* Not illustrated.
COMPONENT
Door Assembly Complete, Enameled Steel (does not include Items 3 and 5)
Door Assembly Complete, Stainless Steel (does not include Items 3 and 5)
Door Pin Assembly
Spring, Door Pin
Handle, Door, Wireform, Stainless Steel (must be ordered separately)
Screw, #10 x ½” Phillips Head, Zinc Plated
Hinge, Door, Universal (must be ordered separately)
Panel, Door, Outer
Liner, Door
Magnet, Door
2-25
8
3
12
1
33
2
2-26
22
11
13
4
10
9
23
7
5
Compression
washers
31
24
Steel flat washer
over plastic washer
32
6
30
29
25
26
27
28
14
19
20
21
17
18
15
DRAIN AND FILTRATION SYSTEM COMPONENTS
Drain System Components
Item
*
1
2
3
4
5
6
7
8
9
10
*
11
Part #
826-0877
810-0396
809-0071
826-1375
816-0032
826-1348
816-0021
826-1382
900-0757
823-0717
823-0718
813-0284
Component
Kit, Clamp Service (Contains 2 each of Items 1-3 and 1 of Item 4)
Clamp Section (Requires 2 per connection)
Nut, ¼–20
Screw, 10–32 X ¾
Seal (Connection Gasket)
Cover, Clean-out (Pkg. of 5)
Gasket, Clean-out
Wing Nut, Clean-out Cover Retaining (Pkg. of 10)
Cover, Drain End
Full Vat, 15.5-inches Long
End, Full Vat, 8.12-inches Long
Nipple, 1-inch x ¾-inch (connects drain valve to drain tube)
Grommet, Drain Tube
816-0092
1.50-inch I.D.
816-0091
1.75-inch I.D. (used on FM I units built prior to February 1990 only)
12
826-1345 Washer, Drain Tube Retaining (Pkg of 25) (1⅜-in. ID x 23/16 -in. OD)
13
809-0347 Nut, Drain Tube Retaining
14
823-0731 Extension, Spreader Cabinet, 15.5-inches Long
15
823-0719 Drain Outlet, Fixed
16
806-4068 Drain Outlet Assembly, Swivel
17
823-1091
Drain Tube, Swivel
18
816-0083
O-Ring, 2.5-inches ID
19
823-1092
Collar, Drain
20
810-0388
Knob, Clamping
21
809-0115
Screw, 10–32
22
810-1569 Valve w/Handle, 1.25-inch Drain (for use on MJ45 units)
23
810-1568 Handle w/Lock, Drain Valve
24
810-1020 Valve, 1.25-inch Drain (for use on FM45 units)**
25
806-8137 Bracket, Drain Safety Switch
26
816-0220 Insulation, Drain Safety Switch
27
807-2103 Switch, Drain Safety
28
900-2841 Cover, Drain Safety Switch
29
809-0237 Nut, 4-40 Keps Hex
30
809-0540 Nut, ½-inch 2-Way Lock
31
810-0820 Handle, Drain Valve w/o Lock
32
816-0211 Sleeve, Drain Valve Handle
33
812-1226SP Extension, Drain
** Not illustrated.
** For old-style valve with welded-on switch bracket, use 823-1363.
2-27
Filter Magic II Filter Pan Assemblies
4
9
1
10
9
5
12
11
10
3
11
7
Fitting on outside
bottom of inner pan.
8
8
7
6
A
Item
A
B
1
2
3
4
5
6
*
*
*
Part #
806-9255SP
823-2751SP
806-6093SP
806-4338SP
823-1360SP
806-5282SP
823-1731SP
823-1361
824-0291
910-1350
816-0117
806-4373
811-0861
811-0746
7
810-0005
8
810-0006
9
824-0416
10
810-1406
11
900-8827
12
810-0180
*
803-0170
*
803-0002
* Not illustrated.
B
2
Component
One-Piece Filter Pan Assembly (Items 7, 8, 10, 11, and 12)
One-Piece Filter Pan
Two-Piece Pan Assembly (Unique components are listed below.)
Outer Pan Assembly (Items 1, 3, 4, 5, 7, 8, and 806-4373)
Outer Pan
Inner Pan Assembly (Items 2, 6, 10, 11, and 12)
Inner Pan
Base, Filter Pan Assembly
Cover, Suction Tube
Clamp, Suction Tube
O-Ring, .609 OD
Heater Strip Assembly
Insulation, Foam (50-foot/15m roll
Tape, Aluminum Insulation (50-yard/46m roll)
Components Used in Both Designs
Caster, Rigid
Caster, Swivel
Crumb Screen
Hold Down Ring Assembly
Sanagrid Filter Screen
Handle, Filter Pan
Paper, Filter (100 sheets)
Powder, Filter (80 1-cup applications)
2-28
12
FRYPOT ASSEMBLIES AND COMPONENT PARTS
15
1
5
10
16
12
2
11
4
3
16
11
6
14
13
7
8
ITEM
1
PART #
106-2549SP
806-3810SP
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
823-3887SP
823-0921SP
806-5778SP
810-0424
806-5567SP
806-1095SP
809-0409
810-0647
900-1090
806-5566SP
900-6441
812-0249
812-0248
816-0602
812-0269
826-1374
809-0173
809-0170
9
17
18
12
COMPONENT
Frypot Assemblies, Complete (Items 2, 3, 5, 6, and 10-18)
Stainless Steel
Cold Rolled Steel
Frypot Assembly, without Insulation
Stainless Steel (integral component of 106-2549SP)
Cold Rolled Steel (integral component of 806-3810SP)
Flue Deflector Box Assembly,
Deflector, Rear Burner (integral component of Item 3)
Flue Assembly
Front Baffle Assembly
Screw, Pilot Light Cover (integral component of Item 6)
Holder, Pilot Light Cover Screw (integral component of Item 6)
Cover, Pilot Light (integral component of Item 6)
Rear Combustion Chamber Panel Assembly
Panel, Combustion Chamber Side
Insulation, Frypot Side, Outer Layer
Insulation, Frypot Side, Inner Layer
Insulation, Kaowool Blanket, ½ X 14 X 4 (trim to fit)
Insulation, Kaowool Blanket, ½ x 14 x 14
Screw, #10 X ½-inch Washer Hex Head (Pkg. of 25)
Clip, Tinnerman
Screw, #14 X ¾-inch Slotted Pan Head
2-29
2-30
14
18
19
4
17
2
15
16
Detail of Motor, Pump, and
Disconnect Components
1
10
13
12
6
11
7
8
3
8
4
5
8
8
20
8
9
9
8
Item shown
disproportionately large for
clarity.
OIL RETURN PLUMBING AND HANDLE COMPONENTS
ITEM
1
PART #
826-1712
826-1756
826-1270
*
806-6728SP
2
826-1264
3
813-0265
4
813-0062
5
813-0368
6
813-0156
7
813-0003
8
810-1057
*
810-1668
9
813-0275
10
810-0278
11
902-0883
12
813-0165
13
813-0022
14
823-1356
15
826-1392
16
816-0102
17
900-1472
18
910-1627
19
813-0330
20
806-4694SP
*
813-0117
*
807-1600
*
807-1601
*
807-1598
*
807-1599
*
807-2016
*
807-1408
*
807-2050
*
811-0746
* Not illustrated
COMPONENT
Pump Motor
100-120 VAC 50/60Hz (includes gasket 816-0093)
208 VAC 50/60 Hz (includes gasket 816-0093)
230-250 VAC 50/60 Hz (includes gasket 816-0093)
Pump Motor Wiring Assembly (used with above motor kits)
Pump, 4 GPM (15 LPM) (includes gasket 816-0093 and mounting screws)
Nipple, ½-inch x 2 ½-inch
Elbow, ½-inch x 90º
Nipple, ½-inch x 16-inch
Pipe Plug, ½-inch
Tee, ½-inch
Flexline, 13-inch Oil Return (has female ends)
Adapter, Male (used with Item 8; two required)
Nipple, ½-inch x 9-inch
Valve, ½-inch Ball
Handle, Valve
Elbow, ½-inch x 90º Street
Nipple, ½-inch Close
Disconnect Fitting
O-Ring (pkg of 5)
Grommet, Oil Diverter
Diverter, Oil
Bracket, Male Disconnect Support
Bushing, ½-inch NPT to ½-inch Tube
Contactor Block Assembly
Nipple, ½-inch x 3½-inch
Thermal Switch, 100-120V Baldor Motors
Thermal Switch, 200-250V Baldor Motors
Thermal Switch, 100-120V Magnatek Motors
Thermal Switch, 200-250V Magnatek Motors
Wiring Harness, Controller to Filter
Heater Strip, 120VAC 50W, 70-inch
Heater Strip, 250VAC 90W, 70-inch
Tape, Aluminum (2-inch x 50-yard (46m) roll)
2-31
THROUGH MARCH 2001
APRIL 2001 AND LATER
10
6
6
7
12
21
11
13
20
18
19
15
10
8
15
1
16
8
12
2
3
9
13
11
14
1
10
9
11
3
14
16
22
17
4
5
5
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
PART #
807-2103
930-0839
810-1999
900-1853
814-0047
900-0239
920-0220
809-0200
826-1381
810-0220
809-0142
809-0056
809-0104
809-0247
826-1359
826-1366
200-0938
810-1165
810-0285
200-1059
809-0601
200-0821
COMPONENT
Microswitch
Bracket, Microswitch
Bracket, Valve Handle
Handle, Oil Return
Sleeve, Handle
Arm, Oil Return Valve
Linkage, Oil Return Valve
Washer, Flat
Washer, Nylatron (Pkg of 10)
Spacer, Tubular, .493 OD
Screw, 5/16 – 24 x ¾” Hex Head
Nut, 5/16 – 24, Hex Head, Nylon Lock
Screw, 4 – 32 x ½” Slotted Truss Head
Nut, Keps Hex, 8 – 32
Screw, 4 – 40 x ¾” Slotted Pan Head (Pkg of 25)
Nut, Keps Hex, 4 – 40 (Pkg of 25)
Handle, Oil Return
Washer, Teflon 0.372 I.D. X 0.753 O.D.
Swivel, Oil Return Linkage Rod
Rod, Oil Return Linkage
Clip, Clevis
Bracket, Microswitch
2-32
POWER SHOWER ASSEMBLY
5
1
4
2
ITEM
1
2
3
4
5
PART #
806-4503SP
809-0415
826-1344
826-1390
814-0001
3
COMPONENT
Power Shower Assembly, Complete
Screw, Cleanout
O-Ring (Pkg of 5)
Seal (Gasket) (Pkg of 5)
Grip, Handle
2-33
TEMPERATURE PROBE, THERMOSTATS, AND RELATED COMPONENTS
9
1
2
4
3
5
8
4
7
ITEM
1
2
3
4
5
6
7
8
9
PART #
806-4206
826-1177
806-7550
807-2274
807-0280
812-1256SP
806-3910
806-0183
210-0681
6
COMPONENT
Temperature Probe, Minco
Thermostat, Non-CE 425°F High-Limit (see NOTE 1)
Thermostat, CE 218°C High-Limit (see NOTE 2)
Thermostat, High Limit
Adapter, High-Limit Thermostat (used only with Robertshaw gas valves)
Adapter Kit, High-Limit Thermostat to Honeywell Gas Valve
Thermostat Assembly, Navy High-Limit (push-button reset)
Thermostat Assembly, Operating
Probe Guard
NOTE 1: Kit 826-1177 (Item 2) contains high-limit thermostat 807-7224 (Item 4), Adapter
807-0280 (Item 5) and an assortment of connectors to allow it to be configured for use on several
different Robertshaw valves.
NOTE 2: Assembly 806-7550 (Item 3) contains high-limit thermostat 807-2274 (Item 4) and
screw-in gas valve adapter kit 812-1256SP (Item 6) for connection to Honeywell gas valves.
2-34
WIRING ASSEMBLIES/HARNESSES AND REMOTE CABLE ASSEMBLIES
806-2079SP
806-8555SP
106-1822SP
106-1804SP
806-4798SP
806-6708SP
807-3699
806-9777SP
806-9778SP
806-9779SP
806-9780SP
806-9781SP
826-1560
806-3549SP
806-6705SP
806-4214SP
806-4215SP
Wiring Assemblies and Harnesses
100-120V Basket Lift Universal Motor (6-Pin female w/6 wires plus 1 separate wire)
208-240V Modular Basket Lift Motor (6-Pin female w/6 wires plus 4 separate wires)
100-120V Modular Basket Lift Motor (12-pin female w/5 wires)
208-250V Modular Basket Lift Motor (12-pin female w/5 wires plus 3 separate wires)
Basket Lift Power, Non-CE (6-pin male w/6 wires; connects to 806-2079SP or 806-8555SP)
Basket Lift Power, CE (6-pin male plus 806-4798)
Basket Lift Power, Non-CE/CE (12-pin male w/6 wires, connects to 106-1822SP or 106-1804SP)
Thermostat Control Universal (control panel-end connections)
Thermostat Control Universal (component shield-end connections)
Basket Lift Universal (control panel-end connections)
Basket Lift Universal (basket lift-end connections)
Wiring Bundle, Component Shield to Controller and Fryer Components (21-wire bundle)
Kit, 45 Series Wiring (contains 806-9777SP through 806-9781SP)
Interface Board (interface board to fryer components; 12-pin male w/5 wires)
CE Non-Direct Wiring Power Supply (power cords joined in junction box)
Fryer to Fryer Drain Safety Switch (2-pin male w/two wires and 2-pin female w/two wires)
Fryer to Filter Drain Safety Switch (2-pin male w/two wires and 2-pin female w/two wires)
NOTE: Assemblies 806-2079SP, 806-9777SP through 806-9781SP and kit 826-1560 are
“universal” in nature. That is, they contain all wires and connectors necessary for all configurations
of the application described. Consequently, there may be “extra” wires that are not needed in a
particular configuration. Any extra wires should be removed when the assemblies are installed to
preclude later confusion.
Remote Computer/Controller to Interface Board Cables
Each of these assemblies has two 15-pin male connectors, and a 15-wire cable looped through a ferrite ring.
Only the length of the cable varies.
806-2071
1.0 foot (30.5cm)
806-3383
15.0 feet (4.6m)
806-3388
20.0 feet (6.1m)
806-4318
30.0 feet (9.1m)
Remote Computer/Controller Cable Assemblies
Each of these assemblies has one 15-pin male connector, one 15-pin female connector, and a 15-wire cable.
Only the length of the cable varies.
806-3528
7.5 feet (2.3m)
806-3529
8.5 feet (2.6m)
806-3530
10.5 feet (3.2m)
806-3531
12.6 feet (3.8m)
Remote Computer/Controller Cable Assemblies w/Junction Box and Mounting Bracket
Each of these assemblies consists of a 4 X 4-inch junction box and mounting bracket assembly with one to
four 15-pin female connectors and one to four 15-wire cables with a 15-pin male connector on the free end
of each cable.
806-8350
One Computer/Controller
806-8349
Two Computers/Controllers
806-8348
Three Computers/Controllers
806-8351
Four Computers/Controllers
2-35
WIRING CONNECTORS, PIN TERMINALS, AND POWER CORDS
1
6
11
ITEM
PART #
*
*
*
807-0154
806-6229SP
807-1685
1
807-1068
2
807-0158
3
807-0156
5
807-0159
5
807-0875
6
807-1067
7
807-0157
8
807-0155
9
807-0160
10
807-0804
11
826-1341
12
826-1342
13
807-2518
* Not illustrated.
2
3
7
8
12
5
4
9
10
13
COMPONENT
Power Cords
100/120V–15A w/grounded plug
100/208/240V–15A, w/o plug
100/208/240V–18A, w/o plug
Connectors
2-Pin Female
6-Pin Female
9-Pin Female
12-Pin Female
15-Pin Female
2-Pin Male
6-Pin Male
9-Pin Male
12-Pin Male
15-Pin Male
Terminal, Female Split Pin (Pkg of 25)
Terminal, Male Split Pin (Pkg of 25)
Plug, Mate-N-Lock (Dummy Pin)
2-36
THIS PAGE INTENTIONALLY LEFT BLANK.
Frymaster, L.L.C., 8700 Line Avenue, PO Box 51000, Shreveport, Louisiana 71135-1000
Shipping Address: 8700 Line Avenue, Shreveport, Louisiana 71106
TEL 1-318-865-1711
FAX (Parts) 1-318-688-2200
PRINTED IN THE UNITED STATES
SERVICE HOTLINE
1-800-551-8633
(Tech Support) 1-318-219-7135
819-5665
NOV 2003
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