FE155 Rethermalizer

FE155 Rethermalizer
Service and Parts
Frymaster, a member of the Commercial Food Equipment Service Association, recommends
using CFESA Certified Technicians.
24-Hour Service Hotline 1-800-551-8633
PRINTED IN THE USA
www.frymaster.com
Email: [email protected]
OCT 2008
*8196440*
Please read all sections of this manual and retain for future reference.
NOTICE
This appliance is intended for professional use only and is to be operated by qualified
personnel only. A Frymaster 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.
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
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.
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.
DANGER
The front ledge of the unit is not a step. Do not stand on the rethermalizer. Serious injury can
result from slips or contact with the hot water.
DANGER
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any
other cooking appliance.
WARNING
No structural material on the fryer should be altered or removed to accommodate placement of
the fryer under a hood. Questions? Call the Frymaster Service Hotline at 1-800-551-8633.
ii
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 frypot. 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.
IMPORTANT
Safe and satisfactory operation of Frymaster equipment depends upon its proper installation.
Installation MUST conform with local codes, or in the absence of local codes, to European
Community (CE) Standards.
COMPUTERS
FCC
This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions:
1) This device may not cause harmful interference, and 2) This device must accept any interference
received, including interference that may cause undesired operation. While this device is a verified Class
A device, it has been shown to meet the Class B limits.
CANADA
This digital apparatus does not exceed the Class A or B limits for radio noise emissions as set out by the
ICES-003 standard of the Canadian Department of Communications.
Cet appareil numerique n’emet pas de bruits radioelectriques depassany les limites de classe A et B
prescrites dans la norme NMB-003 edictee par le Ministre des Communcations du Canada.
DANGER
THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE
CANCER AND/OR BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
Operation, installation, and servicing of this product could expose you to airborne particles of
glasswool or ceramic fibers, crystalline silica, and/or carbon monoxide. Inhalation of airborne
particles of glasswool or ceramic fibers is known to the State of California to cause cancer.
Inhalation of carbon monoxide is known to the State of California to cause birth defects or other
reproductive harm.
NOTICE
The Commonwealth of Massachusetts requires any and all gas products and/or
products attached to a water supply to be installed by a licensed plumber or pipe fitter.
DANGER
Do not use a water jet to clean this appliance.
WARING
Raise the lid slowly. Trapped steam may escape from beneath the lid.
iii
NOTICE
All units shipped without factory supplied cords and plug assemblies must be
hardwired using flexible conduit to the terminal block located on the rear of the unit.
These units should be wired to NEC specifications. Hardwired units must include
installation of restraint devices.
DANGER
Adequate means must be provided to limit the movement of this appliance without
depending on or transmitting stress to the electrical conduit. A restraint kit is provided
with the fryer. If the restraint kit is missing contact your local Frymaster Factory
Authorized Service Center (FASC) for part number 810-3574.
NOTICE
If this equipment is wired directly into the electrical power supply, a means for
disconnection from the supply having a contact separation of at least 3-mm in all poles
must be incorporated in the fixed wiring.
NOTICE
This equipment must be positioned so that the plug is accessible unless other means
for disconnection from the power supply (e.g., a circuit breaker) is provided.
NOTICE
If the electrical power supply cord is damaged, it must be replaced by a Frymaster Dean
Factory Authorized Service Center technician or a similarly qualified person in order to
avoid a hazard.
NOTICE
If this appliance is permanently connected to fixed wiring, it must be connected by
means of copper wires having a temperature rating of not less than 167°F (75°C).
iv
FE155 Rethermalizer
Service and Parts
TABLE OF CONTENTS
Annotated Views
1-1, 1-2
Control Operation
1-3
Functional Description, Wiring Diagram
1-4, 1-5
Component Replacement
1-5, 1-7
Parts
2-1
v
CHAPTER 1: Overview/Component Replacement
1.1
Finding Your Way around the FE155
Overflow
Lid
Upper Level Float Switch
Drain
16.5 Gal vat
8 kW Element
Probe
Inlet
Bezel
Low Level Float Switch
Controller
FE155 Vat
NOTE: The water inlet is
controlled by the main
power switch. It must be
off during draining and
cleaning to ensure the
vat doesn’t refill.
3.1
Introduction
FE155
1-1
CHAPTER 1: Overview/Component Replacement
Main Power Switch
Main Power Switch
Fuses
Contactor
Drain handle
Cabinet Interior
Solenoid
Temp
probe
Check
valve
Hi-limit
Hi-limit
Inside control box
Probe
Drain extension
1-2
CHAPTER 1: Overview/Component Replacement
1.2
Controller
This equipment uses a specialized controller.
Computer Operation
•
•
•
•
•
Ensure the main power switch (behind cabinet door) is on.
Press either ON/OFF button to turn the computer on.
The computer displays LO as it rises to the preset 190°F setpoint for simmer.
At setpoint, the computer displays alternate between dashed lines, and S inn.
Press a Temperature key to toggle display to actual temperature on the left, setpoint on the
right. Press again to toggle back.
Simmer
•
•
•
Place product in vat and press desired timer key. Display alternates
between S inn and remaining cook time.
COOC appears and an alarm sounds when the cook time elapses. Cook
cycles won’t start if the computer is displaying LO.
Remove the product and press the timer key to halt the alarm.
NOTE: Computer returns to simmer mode
if a boil cook cycle is
not initiated within 15
minutes of pressing
the boil key.
Boil
•
•
•
•
•
•
Press the boil key.
Display changes to boil.
Wait until water boils.
Place product in vat and press the desired timer key.
Temperature keys are inactive.
Display alternates between boil and the remaining
cook time.
COOC appears and an alarm sounds when the cook
time elapses.
1-3
NOTE: Pressing the Boil key with the
computer OFF produces a Code display. ON/OFF keys are inactive.
— Enter 1661 to display the software
version and reactivate the ON/OFF
keys.
— Press any other key four times to
clear display and reactivate ON/OFF
keys without software display.
CHAPTER 1: Overview/Component Replacement
•
•
Remove the product and press the timer key to halt the alarm.
Press Boil key a second time to return to simmer mode.
1.3 Programming
• Remove the bezel (see annotated photo on page 3-1) Lift up and then rotate out at the
bottom, which exposes a keypad beside each timer button.
• Temperature change: Press the temperature key until the current temperature is displayed.
Enter the desired temperature with the key pad.
• An illuminated dot between the last digit and the F indicates the change was accepted.
Temperatures below 155°F and above 210°F can’t be entered. The computer will default to
its lowest setting, 155°F, upon low-temperature entry and to its highest setting, 210°F, upon
high-temperature entry.
• Time change: Press the temperature key until the display alternates between S inn and a
dashed line. Enter the desired time, in minutes and seconds, on the key pad. Press the timer
key to ensure the desired time is in place. Press the timer key a second time to stop the timer.
• Turn the controller OFF. Replace the bezel. Ensure it doesn’t press against the key pads.
1.4 Functional Description
With the main power-switch on, 24-volts is supplied to a relay, which controls the water solenoid. If
the upper float switch is closed (low-water position), the relay is closed and the solenoid opens. It is
not necessary for the controller to be on for the pot to fill.
Twelve volts is also supplied to the controller. The low-level float switch must close to allow signals
from the controller to reach a relay, which, when closed, sends 24 volts through the high limit to the
contactor. The unit won’t heat with the float switch open.
With the controller on, the temp probe monitors the water temperature. The controller calls for heat,
when necessary, by closing the 24-volt relay, which closes the contactor and energizes the elements.
Field Connection Wiring Diagrams
1-4
CHAPTER 1: Overview/Component Replacement
1.5 Replacing the Element
1. Drain the cookpot and disconnect the
cooker from the electrical power supply.
2. Remove the cover from the component
box.
Secure the high-limit
thermostat along the inside of
this leg with two metal wire ties.
3. Make a note of where the leads are connected to the contactor block; disconnect the leads.
4. Cut the wire ties on the fiberglass insulation and remove the insulation from
the element leads.
Standoff
Zinc Washer
5. Cut the metal wire ties which secure the
high-limit thermostat to the element, being careful not to bend the thermostat.
Teflon Washer
Secure the temperature probe
along the inside of this leg with
the probe bracket.
6. Remove temperature probe.
7. Remove the brass nuts from the element
legs and carefully pull the failed element from the cookpot.
Brass Nut
8. Position the replacement element in the cookpot with the standoffs on the bottom of the cookpot,
and thread the element leads through the Teflon washers provided in the element kit. Secure the
element in place with the nuts and zinc washers provided in kit.
9. Install two metal wire ties to secure the high-limit thermostat against the inside of the left leg of
the element.
1-5
CHAPTER 1: Overview/Component Replacement
10. Reposition the temperature probe in its bracket and attach it to the inner right leg of the element.
11. Thread each set of element leads through the fiberglass insulation removed in Step 4 and secure
the insulation in place with a wire tie as close as possible to the brass nut.
12. Thread the leads into the component box and connect them to the contactor block in accordance
with the notes made in Step 3 or the wiring diagram on the door.
13. Replace the cover on the component box. Reconnect the unit to the electrical power supply.
1.6 Replacing the High-Limit Thermostat
1. Drain the cookpot and disconnect the cooker from the electrical power supply.
2. Cut the metal wire ties securing the thermostat body to the element.
3. Press up on the bezel over the computer and pull out at the bottom to remove it.
4. Remove the screws securing the controller and unplug it from its harness.
5. Mark and then disconnect the two leads connected to the thermostat terminals.
6. Loosen the small compression nut, and unscrew the large fitting from the cookpot.
7. Remove the screws securing the thermostat. Pull the thermostat from the cookpot.
8. Insert the replacement thermostat into the cookpot, being careful not to bend the shaft.
9. Position the thermostat along the inside of the left leg of the element and secure it in place with
two metal wire ties.
10. Unscrew the small compression nut from the large fitting on the replacement thermostat. Apply
thread sealer to the large fitting and screw the fitting securely into the cookpot. When the large
fitting is tight, screw the small compression nut into the large fitting and tighten.
11. Coil the thermostat capillary tube as necessary to achieve a neat installation and attach the terminal block to the mounting bracket.
12. Reattach the leads disconnected in Step 5, being sure to reconnect them in accordance with the
wiring diagram on the door of the unit or the markings made when they were disconnected.
13. Return the controller; ensure its harness is fully connected. Secure it with the screws removed in
Step 4.
14. Reconnect the unit to the electrical power supply.
1.7 Replacing the Temperature Probe
1. Drain the cookpot and disconnect the cooker from the electrical power supply.
2. Remove the baskets, basket rack.
3. Mark the wiring harness leads and disconnect them from the probe leads at the push-on connectors.
4. Remove the two screws in the probe bracket.
5. Loosen the small compression nut, and unscrew the large fitting from the cookpot.
6. Carefully pull the probe from the probe block and replace with the new probe.
7. Reattach the leads and reverse Steps 1-5 to complete the procedure, using thread sealer to prevent leaks.
1-6
CHAPTER 1: Overview/Component Replacement
1.8 Replacing a Float Switch
NOTE: The high-level float switch (106-8007) is normally closed. The low-level float switch (1069389) is normally open. A kit, 826-2622, contains one float switch that can be used for either position by flipping the float, which changes its condition.
1. Drain the cookpot and disconnect the cooker from the electrical
power supply.
2. Remove the baskets, basket rack.
3. Remove the nut securing the float switch.
4. Remove the connecting pins from the harness and lift the float
from its position.
5. Route the wires of the replacement float switch through the cabinet and connect them. Remove the float from the float switch kit,
if necessary. Ensure it is positioned properly for the high-level
position (normally closed) or for the low-level position (normally
open).
High-level float switch
6. Secure the new float switch, using thread sealer to prevent leaks.
7. Reposition the rethermalizer and allow it to fill to test the float switch operation.
1-7
FE155 Rethermalizer
CHAPTER 2: PARTS LIST
Accessories
Item
Part #
1
2
3
4
5
6
803-0384
803-0385
803-0386
810-3574
810-0356
810-0357
Component
Rack, support
Rack, master
Basket, insert
Restraint kit
Caster, 5-in, no brake
Caster, 5-in, brake
2-1
FE155 Rethermalizer
CHAPTER 2: PARTS LIST
Contactor Box
Item
Part #
1
2
3
4
5
6
7
8
*
*
*
*
108-0039
807-0012
807-0680
807-0979
807-1683
826-1601
807-3970
807-2284
807-4751
807-0922
807-2278
807-4036
Component
Sound device
Relay, 18 amp, 24V coil
Transformer, 208/240/24V 50/60Hz, 43VA
Transformer, 208/240/12V, 50/60Hz, 20VA
Relay, 12VDC
Thermostat, hi-limit
Block, 3-pole 600V 175A
Contactor, 3-pole 600V 50 amp
Cord set, single phase
Fuse holder
Fuse, 20 amp
Switch, on-off
Controller
Item
Part #
1
*
108-0274
807-4397
Component
FE155 Controller
Harness, controller
2-2
FE155 Rethermalizer
CHAPTER 2: PARTS LIST
Vat, Related Components
Item
Part #
1
*
2
3
4
*
*
*
*
*
826-2622
813-0807
826-2623
823-6263
826-2624
809-0204
230-3071
230-4539
230-0500
809-0500
Component
Float switch, kit
Bushing, ¼ MNPT x 1/8 FNPT for lower float switch
Element kit, 240V
Vat
Temperature probe kit
Washer, Teflon for elements
Bracket, temp probe
Bracket, temp probe, strap
Strap, temp probe
½” screw, SS, probe bracket
2-3
FE155 Rethermalizer
CHAPTER 2: PARTS LIST
Drain, Fill Components
Item
Part #
1
2
3
4
5
6
*
7
8
9
10
*
810-3572
810-3573
810-3243
816-0779
108-0435
810-3569
810-1824
823-6279
816-0639
220-5585
810-3244
811-1141
Component
Hose, water connection, 48”
Adapter, hose to pipe ¼ x ¾ “
Check valve, in-line
Hose, drain
Solenoid, water inlet
Valve, drain, brass 1”
Valve, drain, SS, 1”
Handle, drain
Cap, vinyl
Plate, drain base cover
Clamp, 5/8” hose
Tubing, 3/8 “
* Not Illustrated.
2-4
FE155 Rethermalizer
CHAPTER 2: PARTS LIST
2
4
3
1
8
5
7
6
9
Cabinet Components
Item
Part #
1
2
3
4
5
6
7
8
9
*
*
*
*
222-4530
221-4530
108-0262
230-5472
810-2346
220-5588
230-4998
823-7041
823-7119
810-1374
809-0603
106-9744
106-9745
Component
Cabinet side, left
Cabinet side, right
Door
Handle
Magnet, door
Cabinet base
Hinge, lower
Topcap
Vat cover
Handle, cover
Screw, 3/8x24, handle cover
Hinge assembly, cover, right
Hinge assembly, cover, left
2-5
Frymaster, L.L.C., 8700 Line Avenue, Shreveport, Louisiana 71106
TEL 1-318-865-1711
PRINTED IN THE UNITED STATES
FAX (Parts) 1-318-688-2200
SERVICE HOTLINE
1-800-551-8633
FAX (Tech Support) 1-318-219-7135
819-6440
OCT 2008