Oil Conserving Fryer (OCF30)
Oil Conserving Fryer (OCF30)™
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
www.frymaster.com
E-mail: service@frymaster.com
JAN 2013
*8196688*
NOTICE
IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART FOR THIS MANITOWOC
FOOD SERVICE EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART
PURCHASED DIRECTLY FROM FRYMASTER DEAN, OR ANY OF ITS FACTORY AUTHORIZED
SERVICERS, 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 Factory Authorized Servicer (FAS) 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.
ii
DANGER
No structural material on the fryer should be altered or removed to accommodate placement of
the fryer under a hood. Questions? Call the Frymaster Dean Service Hotline at 1-800-551-8633.
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
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.
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.
NOTICE
The Commonwealth of Massachusetts requires any and all gas products to be installed by a
licensed plumber or pipe fitter.
iii
OCF30™ SERIES GAS FRYERS
TABLE OF CONTENTS
CAUTIONARY STATEMENTS ...................................................................................................................... i
CHAPTER 1: Service Procedures
1.1
Functional Description ................................................................................................................... 1-1
1.2
The Electronic Ignition System ...................................................................................................... 1-1
1.3
Interface Board ............................................................................................................................... 1-2
1.4
Thermostats .................................................................................................................................... 1-4
1.5
Accessing Fryers for Servicing....................................................................................................... 1-4
1.6
Cleaning the Gas Valve Vent Tube ................................................................................................ 1-5
1.7
Checking the Burner Manifold Gas Pressure ................................................................................. 1-5
1.8
Measuring Flame Current ............................................................................................................... 1-6
1.9
Replacing Fryer Components ......................................................................................................... 1-7
1.9.1
Replacing the Controller or the Controller Wiring Harness........................................... 1-7
1.9.2
Replacing the Temperature Probe or High-Limit Thermostat ....................................... 1-7
1.9.3
Replacing the Interface Board ........................................................................................ 1-8
1.9.4
Replacing an Ignition Module ........................................................................................ 1-8
1.9.5
Replacing an Ignitor Assembly ...................................................................................... 1-8
1.9.6
Replacing or Cleaning a Combustion Air Blower.......................................................... 1-9
1.9.7
Adjusting the Air/Gas Mixture ..................................................................................... 1-10
1.9.8
Replacing a Gas Valve ................................................................................................. 1-11
1.9.9
Replacing a Burner Assembly ...................................................................................... 1-12
1.9.10
Replacing the Filter Motor, Filter Pump, or Filter Pump Solenoid Valve ................... 1-13
1.9.11
Replacing the Frypot .................................................................................................... 1-13
1.9.12
Replacing Frypot Insulation and/or Upper Burner Rails.............................................. 1-14
1.10 Troubleshooting and Problem Isolation ....................................................................................... 1-17
1.10.1
Ignition Failure ............................................................................................................. 1-18
1.10.2
Improper Burner Function ............................................................................................ 1-18
1.10.3
Improper Temperature Control .................................................................................... 1-20
1.10.4
Computer Malfunctions................................................................................................ 1-20
1.10.5
Filtration Malfunctions................................................................................................. 1-20
1.10.6
Leakage ........................................................................................................................ 1-21
1.10.7
Basket Lift Malfunctions.............................................................................................. 1-21
1.11 Troubleshooting Guides ............................................................................................................... 1-23
1.11.1
Troubleshooting the 24 VAC Circuit ........................................................................... 1-23
1.11.2
Troubleshooting the Gas Valve .................................................................................... 1-26
1.11.3
Troubleshooting the Temperature Probe ...................................................................... 1-27
1.11.4
Replacing the Transformer, Reset Switch or Filter Relay............................................ 1-27
1.12 Probe Resistance Chart ................................................................................................................. 1-28
1.13 ATO (Automatic Top-Off) Service Procedures ........................................................................... 1-28
1.13.1
ATO (Automatic Top-Off Troubleshooting ................................................................. 1-28
1.13.2
ATO (Automatic Top-Off) Board Positions and Harnesses......................................... 1-30
1.13.3
Replacing the ATO Board, Pump Relay or Transformer ............................................. 1-31
1.13.4
Replacing the ATO Pump ............................................................................................ 1-31
1.13.5
Replacing the ATO Solenoid ....................................................................................... 1-31
1.13.6
Control Power Reset..................................................................................................... 1-32
1.13.7
Testing ATO RTD Probes ............................................................................................ 1-32
1.14 3000 Computer Service Procedures ............................................................................................. 1-32
1.14.1
3000 Computer Troubleshooting ................................................................................. 1-32
1.14.2
3000 Useful Codes and Passwords............................................................................... 1-35
iv
OCF30™ SERIES GAS FRYERS
TABLE OF CONTENTS cont.
1.15
1.16
1.17
1.18
1.14.3
Service required Errors................................................................................................. 1-35
1.14.4
Error Log Codes ........................................................................................................... 1-36
1.14.5
3000 Menu Summary Tree ........................................................................................... 1-37
1.14.6
3000 Controller Pin Positions and Harnesses............................................................... 1-38
Loading and Updating Software Procedures ................................................................................ 1-39
Principal Wiring Connections ...................................................................................................... 1-40
Wiring Diagrams .......................................................................................................................... 1-40
1.17.1
FPGL230/430 Wiring................................................................................................... 1-41
1.17.2
FPGL330 Wiring .......................................................................................................... 1-42
1.17.3
FPGL430 Wiring .......................................................................................................... 1-43
1.17.4
Modular Basket Lift (100/120V).................................................................................. 1-44
1.17.5
Modular Basket Lift (208/250V).................................................................................. 1-45
1.17.6
Basket Lift Interface Wiring ........................................................................................ 1-46
Simplified Wiring Diagrams ........................................................................................................ 1-47
1.18.1
FPGL30 Full-Vat Dual-Spark Module ........................................................................ 1-47
1.18.2
FPGL30 Full-Vat Single-Spark Module ..................................................................... 1-48
1.18.3
FPGL30 Dual-Vat Single-Spark Module .................................................................... 1-49
1.18.4
FPGL30 Series Simplified Wiring ............................................................................... 1-50
1.18.5
FPGL30 Series Data Network Flowchart..................................................................... 1-51
1.18.6
Shortening Melting Unit Wiring Diagram ................................................................... 1-52
1.18.7
Bulk Oil Wiring Diagram ............................................................................................. 1-53
1.18.8
Bulk Oil Box Wiring Diagram ..................................................................................... 1-54
CHAPTER 2: Parts List
2.1
Accessories ..................................................................................................................................... 2-1
2.2
Basket Lift Assemblies and Associated Parts................................................................................. 2-2
2.3
Doors, Sides, Flue Caps, Top Caps and Casters ............................................................................. 2-4
2.4
Drain System Components ............................................................................................................. 2-5
2.4.1
Drain Valves and Associated Parts ................................................................................ 2-5
2.4.2
Drain Tube Sections and Associated Parts ..................................................................... 2-6
2.5
Electronics and Electrical Components .......................................................................................... 2-7
2.5.1
Computers and Associated Components ......................................................................... 2-7
2.5.2
Component Boxes .......................................................................................................... 2-8
2.5.3
Transformer Boxes ....................................................................................................... 2-10
2.6
Wiring ........................................................................................................................................... 2-12
2.6.1
Main Wiring Harnesses ................................................................................................ 2-12
2.6.2
3000 and ATO Wiring Harnesses ................................................................................ 2-13
2.7
Frypots and Associated Components ........................................................................................... 2-14
2.7.1
Full-Vat Frypot Components ....................................................................................... 2-14
2.7.2
Dual-Vat Frypot Components ...................................................................................... 2-16
2.7.3
Frypot Probes and Thermostats .................................................................................... 2-18
2.8
Gas Valves, Supply and Combustion System Components ......................................................... 2-19
2.9
Filtration System Components ..................................................................................................... 2-21
2.10 Filter Pump, Motor and Associated Components ......................................................................... 2-22
2.11 Frypot Assemblies and Associated Components.......................................................................... 2-23
2.12 Oil Return System Components ................................................................................................... 2-24
2.13 ATO (Auto Top-Off) Components ............................................................................................... 2-25
2.13.1
JIB (Jug In Box) Basket and ATO Box Assembly ...................................................... 2-25
2.13.2
JIB Cap and Pick Up Assembly .................................................................................. 2-25
2.13.3
ATO (Automatic Top-Off) Pump Assembly ............................................................... 2-26
2.13.4
ATO Top off Manifolds and Components................................................................... 2-27
v
2.14
2.15
2.13.5
Shortening Melting Unit .............................................................................................. 2-28
2.13.6
Bulk Oil Relay Box and Switch .................................................................................. 2-29
2.13.7
Bulk Oil Plumbing ....................................................................................................... 2-30
2.13.8
Bulk Oil Dispose Waste Valve .................................................................................... 2-31
Wiring Connectors, Pin Terminals, and Tools ............................................................................. 2-32
Fasteners ...................................................................................................................................... 2-33
vi
OCF30™ SERIES GAS FRYER
CHAPTER 1: SERVICE PROCEDURES
1.1
Functional Description
OCF30™ series gas fryers contain a welded stainless steel frypot that is directly heated by a high efficiency
infrared burner system, requiring approximately 43% less energy than conventional burners to cook the same
volume.
Self-contained combustion chambers (referred to as “burners”) are fitted into rails attached to the sides of the
frypot, one on each side. Each combustion chamber is fitted with special ceramic tiles that are heated by the
burning of a forced air/gas mixture. The tiles transfer heat to the frypot by means of infrared radiation,
providing much more constant and uniform heat dispersion over the surface of the frypot than do
conventional burners. Because less heat is lost to the atmosphere in the process, compared to “open-burner”
designs, less fuel is required to achieve and maintain a given frypot temperature.
In full-vat units, gas flow to both of the burners is regulated by one electromechanical gas valve. All fryers in
this series are equipped with 24 VAC gas valve systems, and all are configured with electronic ignition.
1.2
The Electronic Ignition System
An ignition module mounted below the component box (located behind the control panel) is connected to an
ignitor assembly at the burner. The ignition module performs five important functions: it provides fuse
protection for the 24-volt circuit, provides an ignition spark, supplies voltage to the gas valve, provides the
alarm circuit (24V) to the controller and proofs the burner flame. The module contains a four second time
delay circuit and a coil that activates the gas valve. Three types are in use. A closed-box design is used in
most fryers, but in some fryers built for export, the module resembles an interface board. A single dual-spark
module is used on current production full-vat fryers.
The ignitor assembly consists of a spark plug, an enrichment tube, and a flame sensor.
At start-up, the power switch is placed in the ON position,
supplying approximately 12-volts DC to the heat-control circuitry
in the controller and to one side of the heat relay coils on the
interface board. If resistance in the temperature probe indicates the
temperature in the frypot is below 180ºF (82ºC), the current flows
through a melt cycle circuit where a timer switch alternately closes
for six seconds and opens for 24 seconds. If the temperature is
180ºF (82ºC) or above, the current flows through a heat circuit,
bypassing the timer switch. In either case, ground is supplied to
the other leg of the heat relay coils, which closes electronic
switches in the 24 VAC circuit to provide current to the ignition
module. Circuitry in the ignition module sends 24 VAC to the gas
valve via a normally closed high-limit switch and a normally
closed drain safety switch. Simultaneously, the module causes the
ignitor to spark for four seconds to light the burner. A flame
sensor verifies the burner ignition by measuring the flow of
microamps through the flame. If the burner does not light (or is extinguished), current to the ignition module
is cut, the gas valve closes, and the ignition module “locks out” until the power switch is turned off and then
back on. A probe monitors the temperature in the frypot. When the programmed setpoint temperature is
reached, resistance in the probe causes the heat cycle circuitry in the controller to cut off current flow through
the heat relay. This in turn cuts off the 24 VAC to the ignition module, causing the gas valve to close.
1-1
1.3
Interface Board
All fryers in this series have an interface board located in the component box behind the control panel. The
interface board provides a link between the controller and the fryer’s individual components without requiring
excessive wiring, and allows the controller to execute commands from one central point.
K2 and K3 are double-pole-double throw (DPDT) relays that supply 24VAC to the ignition and gas valve
circuits, as well as 120VAC to the blower motor. The relays on this board plug into sockets. If a relay fails,
that relay can be replaced.
LEDs (labeled D1 through D7) are arrayed around the board to assist in troubleshooting.
INTERFACE BOARD
LED DIAGNOSTIC LIGHTS
D1
24 VAC to left gas valve (dual vat only)
D2
24 VAC to left ignition module (dual vat only)
D3
24 VAC from transformer
D4
24 VAC to right ignition module
D5
24 VAC to gas valve (right valve if dual vat)
D6
12 VAC from transformer
D7
CE and Japanese units only: air switch closed
NOTE: In full-vat fryers, the relay for the left side (K2) may not be present.
The chart on the following page illustrates current flow through the board, and the table at the top of page 1-4
identifies frequently used test points.
1-2
1-3
FREQUENTLY USED TEST POINTS FOR INTERFACE BOARD 106-6706
TEST
12VAC Power to Controller
METER
SETTING
PINS
50VAC Scale
1 and 3 on J3 or J2
RESULTS
12-18
24VAC Power to Right Module
50VAC Scale
8 on J3 and GROUND
22-28
120 VAC Power
250VAC Scale
11 on J3 and GROUND
110-125
120 VAC Power to Blowers
250VAC Scale
12 on J3 and GROUND
110-125
24VAC Power to Full or Right vat High-Limit
50VAC Scale
9 on J3 and GROUND
22-28
22-28
24VAC Power to Left High-Limit (if present)
50VAC Scale
9 on J1 and GROUND
Probe Resistance (Full or Right Vat) *
R x 1000 OHMS
2 and 6 on J3 or 13 and 14 on J2
**
Probe Resistance (Left - if present) *
R x 1000 OHMS
2 and 6 on J1 or 14 and 15 on J2
**
Probe Isolation
R x 1000 OHMS
6 on J1 or J3 and GROUND
***
High-Limit Continuity (Full or Right Vat)
R x 1 OHM
9 on J3 and Wire 13C on Gas Valve
0
High-Limit Continuity (Left - if present)
R x 1 OHM
9 on J1 and Wire 12C on Gas Valve
0
* Disconnect 15-pin harness from controller before testing probe circuit.
** See Probe Resistance Chart on page 1-28.
*** 5 mega-Ohms or greater.
1.4
Thermostats
OCF30™ series gas fryers have temperature probes located on the front centerline of each frypot. In this type of
thermostat, 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. Circuitry in the controller monitors the probe resistance
and controls burner firing when the resistance exceeds or falls below programmed temperatures (setpoints).
OCF30™ series gas fryers are also 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 highlimit thermostat acts as a normally closed power switch that opens when exposed to temperatures above 425ºF to
450ºF (218ºC to 232ºC). The different types of thermostats have different part numbers for CE and Non-CE models,
and are not interchangeable.
1.5
Accessing Fryers for Servicing
DANGER
Moving a fryer filled with oil may cause spilling or splattering of the hot liquid. Follow the
draining instructions in Chapter 5 of the OCF30™ Series Gas Fryer Installation and
Operation Manual (P/N 819-6687) before attempting to relocate a fryer for servicing.
1. Shut off the gas supply to the unit. Unplug the power cords. Disconnect the unit from the gas supply.
2. Remove any attached restraining devices and relocate the fryer for service accessibility.
3. After servicing is complete, reconnect the unit to the gas supply, reattach restraining devices, and plug in the
electrical cords.
1-4
1.6
Cleaning the Gas Valve Vent Tube
1. Set the fryer power switch and the gas valve to the OFF position.
2. Carefully unscrew the vent tube from the gas valve. NOTE: The vent tube may be straightened for ease of
removal.
3. Pass a piece of ordinary binding wire (.052 inch diameter) through the tube to remove any obstruction.
4. Remove the wire and blow through the tube to ensure it is clear.
5. Reinstall the tube and bend it so that the opening is pointing downward.
1.7
Checking the Burner Manifold Gas Pressure
1. On non-CE fryers only ensure that the gas valve knob is in the OFF position.
Honeywell
ON
OFF
2. Remove the pressure tap plug from the gas valve assembly.
Pressure Tap Plug
Typical Non-CE
Valve Assembly
Typical CE Valve
Assembly
3. Insert the fitting for a gas pressure-measuring device into the pressure tap hole.
4. On non-CE fryers only, place the gas valve in the ON position.
5. Place the fryer power switch in the ON position. When the burner has lit and burned steadily for at least one
minute, compare the gas pressure reading to the pressure for the corresponding gas in the appropriate table on the
following page. The tables list the burner manifold gas pressures for each of the gas types that can be used with
this equipment.
1-5
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
(G25) under 20 mbar
Butane/Propane
(G30) at 28/30 or 50 mbar
Propane
(G31) under 37 or 50 mbar
Single
Vat
7
10
10
17
20
* Belgian G25 = 7,0 mbar
Non-CE Standard
Burner Manifold Gas Pressures
Gas
Pressure
3" W.C.
0.73 kPa
8.25" W.C.
2.5 kPa
Natural
Propane
6. To adjust the burner gas pressure, remove the cap from the gas valve regulator and adjust to the correct pressure.
Non-CE
Valve
CE
Valve
GAS VALVE REGULATOR CAP
7. Place the fryer power switch (and the gas valve in non-CE fryers) in the OFF position. Remove the fitting from
the pressure tap hole and reinstall the pressure tap plug.
1.8
Measuring Flame Current
When the burner flame is properly adjusted, it will produce a current between 2.5 A and 3.5 A. Flame current is
measured by placing a microamp (not milliamp) meter in series with the sensing wire on the ignitor. This is
accomplished as follows:
1. Place the fryer power switch in the OFF position.
1-6
2. Disconnect the sensing wire from one of the burner ignitors and connect it to the positive lead of the meter.
Connect the negative lead of the meter to the terminal from which the sensing wire was removed.
Flame Sensor Wire
3. Place the fryer power switch in the ON position to light the burners. After the frypot temperature reaches 200F
(93C), wait at least one minute before checking the reading. NOTE: The closer the unit is to normal operating
temperature, the more accurate the reading will be.
1.9
Replacing Fryer Components
1.9.1 Replacing the Controller or the Controller Wiring Harnesses
1. Disconnect the fryer from the electrical power supply.
2. Open the control panel by removing the screws on the bottom of the bezel. Carefully lower the bezel.
3. Remove the two screws from the upper corners of the controller. The controller is hinged at the bottom and will
swing open from the top.
4. Unplug the wiring harnesses from the connectors on the back of the controller marking their position for
reassembly and disconnect the grounding wires from the terminals. Remove the controller by lifting it from the
hinged slots in the control panel frame.
Ground Wire Terminal
Ground Wire Terminal
20-Pin Connector
Communication Wires
Locator Wire
3000 controller illustrated. CM3.5 not illustrated.
5. Install the replacement controller. Reverse steps 1 thru 4.
6. Setup the 3000 controller following the instructions on page 4-3 in the Installation and Operation manual. Setup
MUST be performed after replacement. See Frymaster Controller Manual 819-5871 for CM3.5 setup.
7. Once setup is complete on all replaced controllers, reset all control power following the instructions in section
1.13.6 on page 1-33 to readdress the new 3000 controller. Check software version and if necessary update the
software. If a software update was necessary, follow the instructions to update the software in section 1.15 on
page 1-40.
1.9.2
Replacing the Temperature Probe, ATO Probe or High-Limit Thermostat
1.
2.
3.
4.
5.
6.
Disconnect the fryer from the electrical supply.
Drain cooking oil below the level of the probe or thermostat.
Remove the screws on the bottom of the bezel. Carefully lower the bezel.
Remove the top two screws in the upper corners of the controller.
Swing the controller out from the top and allow it to rest on its hinge tabs.
Disconnect the controller wiring harness(es) and ground wire from the back of the controller and remove the
controller by lifting it from the hinge slots in the control panel frame.
7. Disconnect the ignition cables from the ignitors by grasping the boots and gently pulling toward you.
8. Disconnect the flame sensor wires from the flame sensors.
9. Disconnect the sound device lead from the interface board.
1-7
10. If working on the left frypot, cut the wire tie on the wiring bundle and disconnect the main wiring harness 15-pin
connector.
11. Remove the component box mounting screws.
12. Rotate the top of the component box out of the frame and carefully pull it out enough to disconnect the wiring
harness plug from the back of the box. This will leave one set of wires, enclosed in spiral wrap, connected to the
component box.
13. Remove the box and set it atop the fryer to expose the temperature probe and high-limit thermostat.
14. Unscrew the probe or thermostat from the frypot.
15. Apply Loctite® PST56765 pipe thread sealant or equivalent to the replacement part threads and screw the
replacement part into the frypot, torquing to 180 inch-pounds.
16. If replacing the ATO probe, disconnect the harness from the ATO board or extension harness. Ensure when
replacing the new probe that it does not extend past the wall of the frypot before tightening the ferrule.
17. Connect the wires from the new component as follows:
a. If replacing the temperature probe, use a pin pusher to disconnect (one at a time) the red and white leads from
the connector and insert the corresponding leads from the new probe into the plug..
b. If replacing the high-limit thermostat, use a pin pusher to disconnect the lead running to the connector and
insert the corresponding lead from the new thermostat.
c. Disconnect the other lead from the drain safety switch and connect the remaining lead from the new
thermostat.
18. Reverse steps 1 through 13 to complete the procedure.
1.9.3 Replacing the Interface Board
1. Perform steps 1 through 4 from section 1.9.1.
2. Disconnect the wires attached to the interface board, marking or making a note of the wires and terminals to
facilitate reconnection.
3. Remove the nuts at each corner of the interface board and carefully pull it from the studs far enough to allow the
connector on the back of the board to be disconnected, then remove the board from the box. When removing the
board, be careful not to lose the spacers that fit over the studs behind the board.
4. Recover the relay(s) from the failed interface board and install on the replacement board.
5. Reverse the procedure to install the replacement board, being sure that the spacers behind the board are in place
and the computer locator ground wire is attached to a stud.
1.9.4 Replacing an Ignition Module
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Disconnect the fryer from the electrical supply.
Remove the screws on the bottom of the bezel. Carefully lower the bezel.
Remove the top two screws in the upper corners of the controller.
Swing the controller out from the top and allow it to rest on its hinge tabs.
Loosen the nuts attached to the screws of the module. Slide the module towards the rear of the component box
until the nuts drop through the keyholes.
Carefully rotate the module and pull forward. On some units it may be necessary to remove the blower.
Disconnect the wires from the ignition module, marking or making a note of the wires and terminals to facilitate
reconnection.
Remove the screws from the module.
Move the screws and spacers to the new module.
Reverse the procedure to install the replacement module.
1.9.5 Replacing an Ignitor Assembly
DANGER
Drain the frypot or remove the handle from the drain valve before proceeding further.
1. Disconnect the fryer from the electrical supply.
1-8
2. Disconnect the flame sensor wire by carefully pulling its push-on terminal from the terminal strip on the ignitor.
Disconnect the gas enrichment tube at the ignitor-end compression fitting. Disconnect the ignition cable from the
ignitor by grasping its boot and gently pulling toward you. (See photo below)
Flame Sensor Wire
Gas Enrichment Tube
Ignition Cable
3. Remove the sheet metal screws securing the ignitor to the mounting plate and pull the ignitor from the fryer.
4. Reverse the procedure to install the replacement ignitor.
1.9.6 Replacing or Cleaning a Combustion Air Blower
1.
Disconnect the blower wiring harness, remove the blower assembly mounting nuts, and remove the blower
assembly from the fryer. If cleaning the motor, continue with Step 2; otherwise, install the replacement blower,
reconnect the wiring harness, and then go to Step 6.
Blower assembly
mounting nuts
Wiring connection
2. Remove the blower motor shield and separate the blower motor from the housing as shown in the illustration
below.
Remove these screws to
remove the shield from the
blower assembly.
Remove these nuts to
separate the blower
motor from the housing.
3. Wrap the motor with plastic wrap to prevent water from entering it. Spray degreaser or detergent on the blower
wheel and the blower housing. Allow it to soak for five minutes. Rinse the wheel and housing with hot tap water,
then dry with a clean cloth.
NOTICE- Australia Only
The air pressure switch on the combustion blower should read: Full Vat units-122pa (0.5
inches W.C.) and for Split Vat units-180pa (0.72 inches W.C.).
1-9
Wrap the motor and wires
with plastic wrap or a
plastic bag.
Blower Housing
Blower Wheel
4. Remove the plastic wrap from the blower motor assembly. Reassemble the blower motor assembly and blower
housing. Reinstall the blower shield.
5. Reinstall the blower assembly in the fryer and reconnect the wiring disconnected in Step 1.
6. Light the fryer in accordance with the procedure described in Chapter 3, Section 3.2.2 of the OCF30™ Series Gas
Fryer Installation and Operation Manual (P/N 819-6687).
7. After the burners have been lit for at least 90 seconds, observe the flames through the burner viewing ports
located on each side of the combustion air blower.
Right
Viewing Port is
behind motor.
Left Viewing
Port.
The air/gas mixture is properly adjusted when the burner manifold pressure is in accordance with the applicable
table on page 1-6 and the burners display a bright orange-red glow. If a blue flame is observed or if there are dark
spots on a burner face, the air/gas mixture requires adjustment. NOTE: Opening the air shutter too much may
result in whistling. It should not be more than 1/3 open.
1.9.7 Adjusting the Air/Gas Mixture
On the side of the blower housing opposite the motor is a shutter plate with a locking nut. Loosen the nut enough to
allow the shutter to be moved, then adjust the position of the shutter to open or close the air intake opening until a
bright orange-red glow is obtained. Carefully hold the shutter in position and tighten the locking nut (see illustration
on the following page).
1-10
On
non-CE
blowers
loosen this nut and rotate
shutter to open or close
air intake.
On CE blowers loosen
both wing nuts and slide
the shutter to adjust the
air intake.
1.9.8 Replacing a Gas Valve
1. Disconnect fryer from electrical and gas supplies.
2. Disconnect the drain safety and high-limit thermostat wires from the gas valve. Mark each wire to facilitate
reconnection.
3. Remove the vent tube (on non-CE fryers) and the enrichment tube fitting from the valve. Disconnect the flexible
gas line(s).
If replacing the left-most valve on any configuration, or the right valve on a two-fryer battery, follow the
instructions below. If replacing valves in other positions, skip to “ALL OTHER VALVES.”
A.
B.
C.
D.
E.
F.
G.
H.
I.
Remove the filter pan from the unit. Remove the door adjacent to the valve being replaced.
Remove the screws that attach the pan rails adjacent to the valve being replaced.
Uncouple the pipe union and remove the gas valve and associated piping from the unit.
Remove the fittings and associated piping from the failed valve and install them on the replacement valve using
Loctite® PST56765 or equivalent pipe thread sealant.
Reconnect the gas valve assembly to the fryer using Loctite® PST56765 or equivalent pipe thread sealant, and
reattach the flexible gas line(s), enrichment tube(s), and the vent tube (on non-CE units). Reconnect the highlimit thermostat wires and drain safety wires to the valve.
Reconnect the fryer to the gas supply and open the cut off valve. Apply a thick soapy solution of water around
each connection to check for gas leaks and ensure there are no bubbles. Eliminate any that are found. There
should be no smell of gas.
Position the pan rail assembly beneath the fryer and rest the rear end of the rail on the cabinet frame. Install the
two nuts and bolts behind the front face of the rail, but do not tighten them. Install the nut and bolt at the rear end
of the filter rail and tighten securely.
Reattach the screws for the pan rails. Install the filter pan in the unit to make sure that all components are properly
aligned.
Reconnect the fryer to the electrical power supply and check for proper operation. When proper operation has
been verified, reinstall the door removed in Step A.
ALL OTHER VALVES
4. Carefully unscrew the valve from the manifold. NOTE: Some models may have the valve attached to the
manifold by means of a pipe union. In such cases, remove the valve by uncoupling the union.
5. Remove all fittings from the old gas valve and install them on the replacement valve, using Loctite® PST56765 or
equivalent pipe thread sealant.
6. Reconnect the gas valve assembly to the fryer using Loctite® PST56765 or equivalent pipe thread sealant, and
reattach the flexible gas line(s), enrichment tube(s), and the vent tube (on non-CE units). Reconnect the highlimit thermostat wires and drain safety wires to the valve.
7. Reconnect the fryer to the gas supply and open the cut off valve. Apply a thick soapy solution of water around
each connection to check for gas leaks and ensure there are no bubbles. Eliminate any that are found. There
should be no smell of gas.
8. Reconnect the fryer to the electrical power supply and check for proper operation.
1-11
1.9.9 Replacing a Burner Assembly
1. Disconnect the unit from the electrical and gas supplies.
2. Remove the gas line and enrichment tube using a 7/16” and 5/8” wrench from the front of the burner.
3. Remove the elbow and tee off the bottom of the burner to ensure easier
removal of the burner.
4. Remove the fryer back.
5. Remove the screws attaching the flue cap to the brace.
6. Remove the top cross brace in the back.
7. Remove the flue by removing the two screws in the rear and one screw in
Figure 1
the front of the flue.
8. Remove all the screws on the flue collector and bend back the tabs and remove the
collector.
9. Remove four screws on the collector insulation plate (see Figure 1).
10. Remove the four nuts and cover of the lower insulation retaining cover (see Figure
2).
11. Carefully remove the insulation.
12. Grasp the burner firmly and slide the burner out the rear of the fryer. Pull it toward
you until it clears the burner channels, taking care not to damage the ceramic tiles in
the process.
Figure 2
13. Slide the burner out the rear of the fryer.
14. Clean all debris from the burner channels and combustion area.
15. Inspect the upper and lower burner rails for cracked or burned out welds.
a. If the welds in the lower rail are cracked or burned out, the frypot must be
replaced. Refer to Section 1.9.11 for procedure.
b. If the welds in the upper rail are cracked or burned out, the upper rail must be
replaced. Refer to Section 1.9.12 for procedure.
16. Wrap a new insulating strip along the top, rear, and bottom edge of the burner.
NOTE: Use P/N 826-0931 for full-vat frypots and P/N 826-0932 for dual-vat
frypots.
17. Carefully slide the replacement burner into the rails starting at the top and lifting
Figure 3
slightly up on the bottom (see Figure 3). Ensure that the insulation is not torn or
damaged.
18. In reverse order, reassemble insulation and holding plates.
19. Install flue collector.
20. Install the flue.
21. Install the cross brace, ensuring the flue cap is secured to the brace.
22. Replace the fryer back.
23. Reattach the elbow, gas line and enrichment tubes to the front of the burner.
24. Fill the frypot with oil. Turn the fryer on; turn off or bypass the melt cycle and operate the unit for at least 10
minutes.
25. Examine the burner flame. The color and intensity on both sides should be the same.
26. Use an inspection mirror to check for leaks in areas that cannot be directly observed.
27. If a leak is detected, tighten all the lower insulation retainer nuts, allow the frypot to heat for five additional
minutes, and repeat steps 25 and 26.
28. If a leak persists, use a rubber hammer and a small block of wood to tap the corners of the lower combustion
chamber insulation retainers. Repeat steps 25 through 27. Repeat this step until no leakage is detected.
1-12
1.9.10 Replacing the Filter Motor, Filter Pump, or Filter Pump Solenoid Valve
1. Disconnect the unit from the electrical power supply.
2. Remove the filter pan from the unit.
3. Position a container beneath the oil return fitting at the front of the cabinet. Disconnect the flexible oil lines from
the fittings, allowing any residual oil to drain into the container.
4. At the rear of the fryer, unplug the left connector (as viewed from the rear of the fryer) from the transformer box.
5. Remove the four nuts and bolts attaching the motor mount to the rear motor mount support.
6. At the front of the fryer, remove the cover plate from the front of the motor and disconnect the motor wires.
7. Place a 1-foot (30.5-cm) length of wood (or similar support) beneath the motor mount near the front of the unit
and remove the two remaining nuts and bolts attaching the motor mount to the front cabinet cross-brace.
8. Carefully remove the support and lower the motor mount to the floor, allowing the rear of the mount to slide
forward and off the rear motor mount support.
9. Disconnect the return flexline from the pump. The motor and pump assembly can now be pulled from beneath the
fryer and the failed component can be removed and replaced.
10. Position the replacement motor and pump assembly beneath the fryer and reconnect the oil return flexline to the
pump. Lift the rear of the motor mount up and onto the rear motor mount support.
11. Lift the front of the motor mount up and support it with a 1-foot (30.5-cm) piece of wood or a similar support.
Install but do not tighten the two nuts and bolts that attach the motor mount to the front cabinet cross-brace.
12. Install and tighten the four nuts and bolts that secure the motor mount to the rear motor mount support.
13. At the front of the fryer, tighten the two nuts and bolts at the front of the motor mount. Reconnect the motor
power wires and reinstall the wiring cover plate.
14. Reconnect the oil return flexline and reinstall the filter pan.
15. Reconnect the unit to the electrical power supply, fill the frypots with oil and check for proper operation.
1.9.11
Replacing the Frypot
1. Disconnect the fryer from the electrical and gas supplies.
2. Remove the filter pan from the unit and drain one frypot at a time into a Shortening Disposal Unit (SDU) or other
appropriate metal container.
DANGER
DO NOT attempt to drain more than one full frypot into the SDU at one time.
3. Open the control panel by removing the two screws on the bottom of the bezel. Carefully lower the bezel.
4. Remove the top screws in the upper corners of the controller.
5. Grasp the upper edge of each controller and swing the controller downward. Unplug the controller wiring harness
and grounding wire from the back of each controller.
6. Remove the controllers by lifting them from the hinge slots in the control panel frame.
7. Disconnect the sound device wire from the interface board.
8. Disconnect the flame sensor wires by carefully pulling the push-on terminals from the terminal strips on the
ignitors. Disconnect the gas enrichment tube at the ignitor-end compression fitting. Disconnect the ignition
cables from the ignitors by grasping the boots and gently pulling toward you.
9. Dismount the topcap by removing the screws on the bottom of each front corner and lifting the topcap straight up.
10. Remove the two mounting screws on each side of the component box and rotate the top of the box out of the
frame. Carefully pull it out enough to disconnect the wiring harness connector from the back of the box. Cut any
ties that prevent the box from being pulled out of the control panel frame.
11. Carefully pull the box clear of the frame and rest it on top of the fryer.
12. Using a pin pusher, remove the temperature probe, high-limit thermostat wires and RTD probe wires from the
plugs or terminals, marking each wire to facilitate re-assembly.
13. Remove the cover from the safety drain switch. Disconnect the wires from the switch.
14. Disconnect any auto top-off sensors if equipped and wiring.
15. Remove the section(s) of drain from the drain valve(s) of the frypot to be removed.
1-13
16. Disconnect the gas lines from the burner orifices and ignitor assemblies.
17. Remove the frypot hold down bracket.
18. Remove the screws in the back panel and inside the flue cap at each end that secure the flue cap to the fryer and
lift it clear of the fryer.
19. Disconnect the oil return line(s) from the frypot to be removed.
20. Carefully lift the frypot from the fryer cabinet.
21. Remove the drain valve(s), temperature probe(s), high-limit thermostat(s), RTD probes, auto top-off sensors if
equipped and ignitor assemblies. Inspect each of these components carefully and install them in the replacement
frypot if they are in serviceable condition. Use Loctite® PST56765 sealant or equivalent on component threads.
NOTE: Some servicers, based upon their experience, recommend that probes and thermostats be replaced
whenever a frypot is replaced; however, this remains the customer’s decision.
20. Reverse steps 1-19 to reassemble fryer.
NOTE: Care should be taken not to over-torque nuts on frypots made of 400-series stainless steel, as this could
tear the material. One turn past hand-tight is sufficient torque.
21. Perform steps 14 through 18 of Section 1.9.9 to ensure that there are no leaks in the burner insulation.
CAUTION
Before installing temperature probe, high-limit thermostat, RTD probe and drain valve on
replacement frypot, clean the threads and apply Loctite® PST56765 thread sealant or
equivalent.
1.9.12 Replacing Frypot Insulation and/or Upper Burner Rails
NOTE: Replacing the burner rails requires completely tearing down the frypot and installing new frypot insulation.
Refer to the frypot exploded view below for component identification.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Remove the frypot per Section 1.9.11.
Remove the burner assemblies (1).
Remove insulation retainers and blanket insulation (2).
Remove the upper oil zone insulation bracket and upper oil zone insulation (3).
Remove the plenum (4).
Remove the front lower combustion chamber insulation retainer and insulation (5) and the front lower combustion
chamber inner insulation retainer and insulation (6). NOTE: Full-vat units have two-piece insulation retainer and
insulation components. Dual-vat units have one-piece components.
Remove the upper combustion chamber insulation retainer and insulation (7).
Remove the inner upper combustion chamber insulation retainer and insulation (8).
Remove the rear lower combustion chamber retainers, back, and insulation (9). NOTE: Full-vat units have twopiece backs and four retainers. Dual-vat units have one-piece backs and two retainers.
Remove the flue assembly (10).
1-14
10
Spacer
2
9
3
Spacer
s
8
11
7
4
1
6
5
Disassembling A Frypot
(Full Vat Illustrated)
See page 1-17 for reassembly illustration.
11. Remove the upper burner rails (11). NOTE: For the following steps, refer to the frypot exploded view on page 116 for component identification.
12. Remove any residual insulation, sealant, and/or oil from the exterior of the frypot.
13. Place the “L” shaped pieces of the combustion chamber insulation (1) in the front and rear corners of both upper
rail-retaining slots. (See page 1-17).
14. Using a mallet and short piece of wood, tap the corner tabs of the combustion chamber over the insulation to
ensure a solid seal of the burner.
15. Install the upper burner rails (2) with the heat deflectors slanting toward the rear of the frypot. The rails will
cover the “L” shaped pieces of combustion chamber insulation previously installed.
16. Place the upper inner combustion chamber insulation and insulation retainers (3) on the top two studs on each side
of the front of the frypot and secure with ¼”-20 washer-nuts. It is normal for the retainers to slice off the
overhanging insulation.
17. Place the lower rear combustion chamber insulation (4) on the lower four studs at the rear of the frypot.
18. Place one 1.625-inch tubular spacer (5) on each of the flue assembly (upper) studs at the rear of the frypot.
NOTE: There are three different sizes of spacers. Verify the size to ensure the correct spacers are installed.
19. Press the flue assembly (6) over the burner rails. It may be necessary to use a rubber mallet or screwdriver to
align the components. Use four ¼”-20 washer nuts to secure the flue assembly. Do not tighten the retainer
nuts at this point. They should be finger-tight only. NOTE: The flue edge will cover one to two inches of the
lower insulation.
20. Install the lower rear combustion chamber back(s) and retainer(s) (7) with the flanged edge(s) against the flue.
Secure with ¼”-20 washer nuts. NOTE: Full-vat units have two-piece backs and four retainers. Dual-vat units
come with one-piece backs and only two retainers.
1-15
21. Insert the burners (9) into the rails to ensure the rail spacing and alignments are correct. The burner should slide
freely into and out of the rails. The upper rail can be bent slightly to increase or decrease tension on the burner
and the edges of the slot can be closed or opened slightly to best fit the burner frame.
22. Carefully wrap a strip of burner insulation (8) tightly around the rear and sides of the burner frame (9), with the
glass-tape side of the strip on the outside. Do not use duct tape or adhesive to secure the strip to the burner
frame.
23. Align the burner to the burner rails while maintaining tension on the insulation strip. Insert the burner at a slight
angle and begin pushing the burner slowly into the rails until it contacts the rear combustion chamber. The fit
should be snug, but not excessively tight.
24. Verify that the burners are flush with the front edge of the burner rails. Remove the excess burner insulation by
cutting with a knife or diagonal pliers. Do not try to tear the insulation!
25. Insert the upper front insulation (10) into its retainer (11), making sure that the holes in each piece are aligned
with one another. Install the assembly with the insulation side toward the frypot and secure with ¼”-20 washernuts. Do not over tighten.
26. Place a washer on each of the four lower studs on the front of the frypot. Install the lower inner front insulation
(12) with the rectangular openings toward the drain valve nipple. Install the lower inner front insulation
retainer(s) (13). NOTE: Full-vat units have a two-piece insulation retainer. Dual-vat units have a one-piece
retainer.
27. If necessary, replace the sight-glasses and insulation (14).
28. Place one washer and one 1.888-inch spacer (15) on each stud. NOTE: There are three different sizes of spacers.
Verify the size to ensure the correct spacers are installed.
29. Insert the front lower insulation (16) into the front lower insulation retainer(s) (17) and install assembly on
frypot. Secure with ¼”-20 washer-nuts. If frypot uses two retainers, connect them together with two ¼” selftapping screws. NOTE: Full-vat units have a two-piece insulation retainer and two pieces of insulation. Dual-vat
units have one-piece components.
30. Return to the rear of the frypot and fully tighten all washer-nuts.
31. Remove and replace the plenum gaskets (18).
32. Place a 0.938-inch spacer (19) on the plenum-mounting studs, and mount the plenum (20). Ensure the gaskets
are clear of the burner tubes by pulling the plenum back slightly. Place a washer on each stud and secure plenum
with ¼”-20 lock-nuts.
33. Install the upper oil-zone insulation (21) by pressing it under the upper combustion chamber metalwork. Secure
the insulation with the bracket (22) and ¼” self-tapping screws.
34. Install the upper burner rail blanket insulation (23). Position any excess insulation toward the top of the frypot.
Avoid overhang past the bottom of the upper burner rail. Overhang in this area will make future burner
replacement more difficult.
35. Cover the insulation with the insulation retainer (24), and secure with ¼” self-tapping screws.
36. Reinstall probes, drain valves, high-limit thermostats, and other pipe fittings using Loctite® PST56765 sealant or
equivalent on the threads.
1-16
6
5
24
4
23
21
1
7
2
22
8
1
16
17
3
15
9
10
20
19
12
11
13
14
18
1.10
Re-assembling A Frypot
(Full-Vat Illustrated)
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.
Problems you are likely to encounter can be grouped into six categories:
1.
2.
3.
4.
5.
6.
Ignition failure
Improper burner function
Improper temperature control
Controller malfunctions
Filtration malfunctions
Leakage
The probable causes of each category are discussed in the following sections. A series of Troubleshooting Guides is
also included at the end of the chapter to assist in solving some of the more common problems.
1-17
1.10.1
Heating (Ignition) Failure
Heating (ignition) failure occurs when the ignition module fails to sense a flame within the 4-second time delay period
and locks out. When this happens, the module sends 24 VAC through the interface board alarm circuit to the
controller.
3000 controllers display “HEATING FAILURE.”
The three primary reasons for ignition failure, listed in order of probability, are problems related to:
1. Gas and/or electrical power supplies
2. Electronic circuits
3. 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 fitting is properly connected,
the fryer is plugged in with connector twisted and locked, 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. 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, refer to Section 1.11.1, TROUBLESHOOTING THE 24 VAC
CIRCUIT.
Some typical causes of heating failure in this category include a defective sensing wire in the ignitor assembly, a
defective module, a defective ignition wire, and a defective ignitor.
Occasionally, a heating failure occurs in which all components appear to be serviceable and the microamp reading is
within specification, but the unit nevertheless goes into ignition failure. The probable cause in this case is an
intermittent failure of an ignition module. When the unit is opened up for troubleshooting, the module cools down
enough to operate correctly; however, when the unit is again closed up and placed back into service the module heats
up and fails.
PROBLEMS RELATED TO THE GAS VALVE
If the problem is not in the 24 VAC circuit, it is most likely in the gas valve, itself. Before replacing the gas valve,
refer to Section 1.11.2 TROUBLESHOOTING THE GAS VALVE.
1.10.2
Improper Burner Function
With problems in this category, the burner ignites but exhibits abnormal characteristics such as “popping,” dark spots
on the burner ceramics, fluctuating flame intensity, and flames shooting out of the flue.
“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

Defective or incorrectly adjusted
combustion air blower

Inadequate make-up air

Heat-damaged computer or ignition module
1-18

Cracked ignitor or broken ignition wire

Defective ignition module

Cracked burner tile (typically causes a very
loud pop).
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 Section 2.3 page 2-4 of the OCF30™ Series Gas Fryer Installation and Operation
Manual (PN 819-6687), and that the pressure remains constant throughout all hours of usage. Refer to
Section 1.7, Checking the Burner Manifold Gas Pressure in this manual for the procedure for checking the
pressure of gas supplied to the burner.
If popping is consistent during all hours of operation, the most likely cause is an insufficient air supply.
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.
If the fryer’s gas and air supplies are correct, the problem is most likely with one of the electrical components.
Examine the ignition module and controller for signs of melting, distortion, and/or discoloration due to
excessive heat build-up in the fryer (this condition usually indicates improper flue performance). A melted or
distorted ignition module is automatically suspect and should be replaced; however, unless the condition
causing excessive heat is corrected, the problem is likely to recur.
Verify that the ignition wire is tightly connected at both ends and free of obvious signs of damage. Again, if
damage is due to excessive heat in the fryer, that problem must also be corrected. Check for proper operation
by disconnecting the wire from the ignitor (spark plug), inserting the tip of a screw driver into the terminal.
With the insulated handle of the screwdriver, hold the shaft near the frame of the fryer as the power switch is
placed in the ON position. A strong, blue spark should be generated for at least four seconds.
DANGER
Make sure you are holding the insulated handle of the screwdriver and not the blade.
The sparking charge is approximately 25,000 volts.
Examine the ignitor (spark plug) for any signs of cracking. A cracked ignitor must be replaced.
If all other causes have been ruled out, examine the burner tiles for any signs of cracking. If cracking is
found, the burner must be replaced.
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.
Dark spots on the burner tiles are the result of an improper air/gas mixture. Adjust the combustion air
blower to reduce the amount of air in the mixture to correct this problem
Flames shooting out of the flue are usually an indication of negative pressure in the kitchen. Air is being
sucked out of the burner 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 1.7.
An excessively noisy burner, especially with flames visible above the flue opening, may indicate that the gas
pressure is too high, or it may simply be that the gas valve vent tube is blocked. If the incoming gas pressure
is correct and the vent tube is unobstructed, the gas valve regulator is probably defective.
Occasionally a burner may apparently be operating correctly, but nevertheless the fryer has a slow recovery
rate (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 include an over-filled frypot, a dirty or out-of-adjustment combustion air
blower, low burner manifold pressure, and/or damaged burner tiles. Adding oil to the frypot during the
recovery process will also cause a slow recovery rate.
If these causes are ruled out, the probable cause is a misadjusted gas valve regulator. Refer to Section 1.7,
Checking the Burner Manifold Gas Pressure, for the gas valve adjustment procedure.
1-19
1.10.3
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 temperature probe. Other components include the
interface board, the controller itself, and the ignition module.
Improper temperature control problems can be categorized into melt cycle problems and failure to control at
setpoint problems.
MELT CYCLE PROBLEMS
Initiation of the melt cycle with 3000 controllers is automatic. Problems may originate from the controller
itself, the temperature probe, or a malfunctioning heat relay on the interface board.
FAILURE TO CONTROL AT SETPOINT
Problems in this category may be caused by the temperature probe, the interface board, or the controller.
1.10.4 Controller Malfunctions
RECOVERY TIME
Recovery time – 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 affect the test if lower ranges are used.
The 3000 controller performs the recovery test each time 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 INFO button once when
the fryer is on. The test results will be displayed in the controller’s LED panel in minutes and seconds. The
maximum acceptable recovery time for OCF30™ series gas fryers is two minutes and twenty-five seconds
(2:25).
1.10.5 Filtration Malfunctions
The majority of filtration problems arise from operator error. One of the most common errors is placing the
filter pad 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 pad, including that the correct size is being used. While you are checking the filter paper/pad, verify
that the O-rings on the filter pan suction tube 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 front of the motor. If the pump then
starts, something caused the motor to overheat. It may
be that several frypots in a large battery of fryers were
being filtered one after the other and the pump became
hot. Letting the pump cool down for at least a halfhour is all that is required in this case. More often, the
pump overheated for one of the following reasons:

F R E E IN G A S E IZ E D P U M P
S e d im e n t P a rtic le
U p fo r re v e rs e
FLO W
D o w n fo r fo rw a rd
Shortening that remained in the pan, after
previous filtering, solidified in the suction
tube recess in the bottom of the pan or the
suction tube, itself. Adding hot oil to the pan and waiting a few minutes will usually correct this
problem. A flexible wire can be used to clean out the suction tube and the recess in the bottom of the
pan. NEVER use compressed air to blow solidified shortening out of the suction tube!
1-20

The operator attempted to filter oil that was not heated. Cold oil is thicker and causes the pump
motor to work harder and overheat.
If the motor hums but the pump does not rotate, 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 and cause the motor to overload, tripping the thermal overload.
Solidified shortening in the pump will also cause it to seize, with similar results.
A pump seized by debris or hard shortening can usually be freed by manually moving the gears with a
screwdriver or other instrument as illustrated on the following page. Make sure power to the pump motor
is off before trying this.
1. Disconnect power to the filter system.
2. Remove the input plumbing from the pump.
3. Use a screwdriver to manually turn the gears.

Turning the pump gears backwards will release a hard particle and allow its removal.

Turning the pump gears forward will push softer objects and solid shortening through the pump and
allow free movement of the gears.
Filter paper/pads that are installed incorrectly will also allow food particles and sediment to pass through and
clog the suction tube recess on the bottom of the filter pan or the suction tube, itself. Particles large enough to
block the suction tube recess or the suction tube may indicate that the crumb tray is not being used.
1.10.6 Leakage
Leakage of the frypot will usually be due to improperly sealed high-limit thermostats, RTD’s, 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 or ends of the frypot are coated with oil, the most likely cause is spillage over the top of the frypot
rather than leakage.
The clamps on the rubber boots that hold the drain tube sections together may loosen over time as the tubes
expand and contract with heating and cooling during use. Also, the boot itself may be damaged. If the
section of drain tube connected to the drain valve is removed for any reason, ensure that its rubber and clamps
are in good condition and properly fitted around the drain tube when it is reinstalled. Also, check to ensure
that the drain tube runs downward from the drain along its whole length and has no low points where oil may
accumulate.
1.10.7 Basket Lift Malfunctions
OCF30™ series gas fryers may be optionally equipped with automatic basket lifts to ensure uniform cooking
times. Basket lifts will always come in pairs, although each operates independently of the other. A modular
basket lift consists of a toothed rod to which the basket lift arm is attached, a reversible-drive gear motor, and
a pair of roller-activated microswitches. A gear on the motor shaft engages teeth in the rod. Depending upon
the direction of motor rotation, the gear drives the rod up or down.
Timing circuitry in the controller initiates and stops operation of the basket lift depending upon the variables
programmed by the operator. When a product button is pressed, the timing circuitry activates a coil to supply
power to the motor, which lowers the basket into the frypot.
When the rod contacts and closes the lower microswitch, power to the motor is cut and the direction of
current flow is reversed; this reverses the direction of motor rotation. When the programmed cooking time
1-21
has elapsed, power is again supplied to the motor. The motor raises the basket from the frypot until the rod
loses contact with the upper microswitch, cutting power to the motor and again reversing the direction of
current flow.
Problems with the basket lift can be grouped into three categories:



Binds and jams
Motors and gears
Electronics.
100-120V C onfiguration
208-250V C onfiguration
Binding and Jamming Issues
Noisy, jerky or erratic movement of the lifts is usually due to lack of lubrication of the rods and 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 is 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 Issues
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.
Correct the problem 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. This cannot be repaired and the motor must be
replaced.
If power is reaching the motor but the motor fails to run, it is burned out and must be replaced.
Electronic Issues
Within this category are problems associated with the relays, microswitches, capacitors, resistors, interface
board, wiring, and controls. The most common problem in this category is a lift that continuously travels up
and down. This is usually caused by a microswitch that is out of adjustment.
1-22
Troubleshooting the electronics of the basket lift is the 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 the applied line voltage. The wiring
diagram on the pages 1-44 and 45 identifies the components and wiring connection points.
1.11
Troubleshooting Guides
The troubleshooting guides on the following pages are intended to assist service technicians in quickly
isolating the probable causes of equipment malfunctions by following a logical, systematic process. An
additional set of operator troubleshooting guides are contained in Chapter 7 of the OCF30 Series Installation
and Operation Manual. It is suggested that service technicians thoroughly familiarize themselves with both
sets.
1.11.1 Troubleshooting the 24 VAC Circuit
Prior to checking for problems associated with the 24 VAC circuit, ensure that the unit is connected to a
power supply, the drain valve is fully closed, and the controller is on and is calling for heat (green dot appears
under heat indicator and display toggles between LOW TEMP).
NOTE: All voltage measurements must be made within 4 seconds of the unit calling for heat. If unit does not
fire within 4 seconds, ignition modules will lock out and controller must be turned off, then on to reset.
The following processes will assist you in troubleshooting the 24 VAC circuit and ruling it out as a probable
cause:

24 VAC is not present on the interface board J3 pin 9 (LED 5 (GV)).
1. If LED 3 is not continually lit, the probable causes are a failed 24 VAC transformer or failed wiring
between the transformer and interface board.
2. If LED 3 is continually lit, check the right PWR terminal (LED 4) for 24 VAC. On dual units, also
check the left PWR terminal (LED 2) for 24 VAC. Verify that the F2 fuse is not blown.
a. If 24 VAC is not present, the probable cause is a failed interface board, blown fuse or a defective
heat relay.
b. If 24 VAC is present, check for 24 VAC on V1S (or V1D and V2D, if dual unit)..
i.
If 24 VAC is not present, check the fuses. If they are good, the probable causes are failed
ignition module(s) or a failed interface board. Replace the questionable ignition module with
one known to be good to isolate the cause.
1-23
ii. If 24 VAC is present, the probable cause is a failed interface board.

24 VAC is present on interface board J3 pin 9 (LED 5 (GV)) and, on dual units, on J1 pin 9 (LED 1
(GV)).
1. If 24 VAC is not present across the gas valve main coil (MV terminals), probable causes are an open
high-limit thermostat or a failed wire between the interface board and gas valve. Be sure to check both
valves on dual units.
a. Check continuity of high-limit thermostat and drain safety switch. If both are zero, problem is in
wiring.
2. If 24 VAC is present across the gas valve main coil (MV terminals), the 24 VAC circuit is working
and the problem may be with the gas valve. Be sure to check both valves on dual vat units.
1-24
1-25
1.11.2 Troubleshooting the Gas Valve
Prior to checking for problems associated with the gas valve, ensure that the unit is calling for heat. Also, for
non-CE units, verify that the gas valve is in the ON position.
The following processes will assist you in troubleshooting the gas valve and ruling it out as a probable cause:


If 24 VAC is not present across gas valve main coil, the probable cause is the 24 VAC circuit. Refer to
the 24 VAC circuit troubleshooting guide.
If 24 VAC is present across gas valve main coil, check the incoming gas pressure and compare to the
tables on page 2-4 of the Installation and Operation manual.
1-26
1. If incoming gas pressure is not correct, the probable cause is a problem with the gas supply to fryer.
2. If incoming gas pressure is correct, check the burner manifold gas pressure and compare it to the
tables on page 2-7 of the Installation and Operation manual.
a. If burner manifold gas pressure is not correct, the probable cause is an improperly adjusted or
failed gas valve. Adjust the valve by following the procedure “Check Burner Manifold Pressure”
in Section 1.7 of this manual. If the valve cannot be adjusted, replace it.
b. If outgoing gas pressure is correct, the gas valve is okay.
1.11.3 Troubleshooting the Temperature Probe
CAUTION
Disconnect the 3000 controller before testing temperature probe resistances to avoid
invalid readings
Prior to checking for problems associated with the temperature probe, inspect the probe body for damage
while it is still in the frypot. Remove and replace the probe if it is bent, dented, or cracked. Also, inspect leads
for fraying, burning, breaks, and/or kinks. If found, replace the probe.
The following processes will assist you in troubleshooting the temperature probe and ruling it out as a
probable cause:
Before testing the probe, determine the temperature of the cooking oil using another thermometer or
pyrometer placed at the tip of the questionable probe.


If resistance through J3 pins 2 and 6 (J1 pins 2 and 6 for left side of dual unit) is not approximately
equal to that given in the Probe Resistance Chart for the corresponding temperature, the probe has
failed and must be replaced.
If resistance through J3 pins 2 and 6 (J1 pins 2 and 6 for left side of dual unit) is approximately
equal to that given in the Probe Resistance Chart for the corresponding temperature, measure the
resistance through each of the previously tested pins to ground.
1. If resistance is not 5 mega-Ohms or greater in each pin, the probe has failed and must be replaced.
2. If resistance is 5 mega-Ohms or greater in each pin, the probe is okay.
1.11.4 Replacing the Transformer, Reset Switch or Filter Relay
Disconnect the fryer from the electrical power supply. Remove the cover from the transformer box in the rear
of the fryer to expose the interior of the transformer box. Replace the transformer or filter relay marking the
wires to ease reassembly. Once replaced, reconnect the power. When replacing a filter relay in the
transformer, ensure the 24VAC relay (8070012) is used.
1-27
1.12
Probe Resistance Chart
Probe Resistance Chart
For use with OCF30™ Series fryers manufactured with Minco Thermistor probes only.
F
60
65
70
75
80
85
90
95
100
105
110
115
120
125
OHMS
1059
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
1204
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
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
1.13 ATO (Automatic Top-Off) Service Procedures
The automatic top-off system is activated when the oil level falls below a sensor in the rear of the frypot. A
signal is sent to the ATO board to engage the solenoid to the frypot and turn on the ATO pump. The pump
draws oil from the JIB (Jug In Box) to a port in the rear of the frypot. Once the oil level has satisfied the
sensor, the pump and solenoid turn off.
The ATO board is located inside the box, behind the JIB (see Figure 1). The
power for the ATO board is supplied from the transformer box. The power
passes through the transformer inside the ATO box to the board.
Figure 1 ATO Box
1.13.1 ATO (Automatic Top-Off) Troubleshooting
Problem
Probable Causes
No power to ATO
board
Incorrect vat tops off.
One vat doesn’t top off.
Frypot tops off cold.
Corrective Action
Fill top off system with oil and press the 
(CONFIRM) button.
Controller displays
TOPOFF OIL Top off system out of oil.
EMPTY/CONFIRM
A. Check to ensure J5 on front of ATO
board is fully locked into connector.
A. J5 connection unplugged
B. Ensure fuse located on right side of
B. Fuse blown.
ATO box is not blown.
C. Transformer malfunction
C. Check that proper voltage is present
at transformer. See table in section
1.13.2.
A. Wired incorrectly.
A. Check wiring.
B. Flexlines connected to wrong vat.
B. Switch flexlines to correct vat.
A. RTD, solenoid issue, wire connection or A. Check
RTD,
solenoid,
wire
ATO board issue.
connections or ATO board.
Incorrect setpoint
Ensure setpoint is correct.
1-28
Problem
Probable Causes
A.
B.
C.
D.
E.
Frypots won’t top off. F.
G.
H.
I.
J.
One vat tops off but A.
other vats fail to top B.
off.
Corrective Action
A. Ensure the JIB is not out of oil and
supply line is in the JIB. Replace JIB
and press the  button when
prompted to reset top off system.
B. Remove supply line from pump and
blow air through line towards JIB.
C. Check to see that fryer is heating.
Fryer temperature must be at least
300°F
(149°C).
Check
probe
resistance. If probe is bad, replace the
probe.
JIB out of oil
D. Ensure oil is above 70°F (21°C).
Supply line from JIB is clogged.
E. Power to the ATO board has been cut
Probe temperature lower than setpoint.
off. Restore power to the board and
Temperature in supply line or JIB is too
switch all controllers off and on again
low.
to readdress system.
ATO board power loss
F. Check solenoid to see if functioning
Failed solenoid.
properly.
ATO pump failed or over tightened.
G. Ensure pump is operational. Check
Failed transformer/harness.
voltage to pump. Replace the pump if
Failed ATO board.
defective.
Top-off manifold solenoid failed
H. Ensure transformer in ATO box is
closed.
functioning properly. Check power
from transformer to ATO board.
Ensure all harnesses are plugged
securely into place.
I. Check for proper voltages using the
pin position chart found on page 1-31.
If ATO found defective, replace ATO
board.
J. A pressure switch opens in the pump
with excessive pressure in the top-off
manifold, shutting down the pump.
Clear or replace solenoid.
A. Check power to the pump. A hot
Failed solenoid
pump suggests a failed solenoid.
Loose wire connection.
B. Ensure all wiring harnesses are
securely connected to ATO board and
solenoids.
1-29
Problem
Probable Causes
3000 displays
SERVICE A. Loose or bad fuse
B. Bad Connection
REQUIRED – ATO
C. ATO Board power loss
BOARD
1-30
Corrective Action
A. Ensure fuse on right side of ATO box
is secure and good. If the controller
above the ATO box is missing power,
check the fuse below the component
box.
B. With the controller OFF, press TEMP
button and ensure the ATO software
version appears.
If not, the
connection between the controller
and the ATO board may be bad.
Ensure the 6-pin CAN connectors are
tight between controller (J6 and J7)
and ATO (J9 or J10) boards.
C. Power to the ATO board has been cut
off. Ensure there is correct voltage to
the ATO transformer. Restore power
to the board and clear any service
required errors.
1.13.2 ATO (Automatic Top-Off) Board Pin Positions and Harnesses
Connector
From/To
Harness #
8075161
Solenoids
J8
8075162(4 or 5 battery)
Top Off Pump Relay
JIB Reset Switch
8075161
Solenoids
8075162(4 or 5 battery)
Top Off Pump Relay
JIB Reset Switch
J4 (Rear) /
J5 (Front)
J3 - Vat 5&6
J2 - Vat 3&4
J1 - Vat 1&2
Transformer
ATO RTD
8074553
1080501 (FV)
1080502 (DV)
J6
J10
Network Resistor
(pins 2 & 3)
or to next ATO Board (4
& 5 vat units)
8074552
J9
3000 J7
8074646
1-31
Pin
#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
1
2
3
4
1
2
1
2
3
4
5
6
1
2
3
4
5
6
Function
Output DV - Vat #1
Output FV - Vat #1
Output DV - Vat #2
Output FV - Vat #2
Output DV - Vat #3
Output FV - Vat #3
Top Off Pump
JIB Reset
24VAC DV - Vat #1
24VAC FV - Vat #1
24VAC DV - Vat #2
24VAC FV - Vat #2
24VAC DV - Vat #3
24VAC FV - Vat #3
Ground
Ground
24VAC Ret
24VAC
12VAC Ret
12VAC
DV - Probe Ground
DV - Probe
FV - Probe Ground
FV - Probe
Ground
CAN Lo
CAN Hi
5VDC+
24VDC
Ground
Ground
CAN Lo
CAN Hi
5VDC+
24VDC
Ground
Voltage
Ground
12VDC
16VDC
24VAC
12VDC
16VDC
24VAC
Wire
Color
Green
Red
Green
Red
Green
Red
Red
Red
White
Black
White
Black
White
Black
Black
Black
Orange
Blue
12VAC
Red
Brown
Ohm
White
Red
White
Red
5VDC
24VDC
5VDC
24VDC
Black
Red
White
Black
Red
White
Black
Red
White
Black
Red
White
1.13.3 Replacing the ATO Board, ATO Pump Relay or Transformer
Disconnect the fryer from the electrical power
supply. Locate the ATO box (see Figure 1 on page
1-28), behind the JIB (Jug In Box). Remove the cover
to expose the transformer and ATO board (see Figure
2). Mark and unplug any wires or harnesses.
Replace the defective component and reattach all
wires or harnesses.
Replace the cover. Once
replaced, reconnect the power. CYCLE POWER
TO ENTIRE FRYER SYSTEM. See section 1.13.6
on page 1-32 to reset control power. Check software
version and if necessary update the software. If a
software update is necessary, follow the instructions
to update the software in section 1.15.
Figure 2
Remove and restore power to ALL controllers after power has been restored to the ATO board. Press the
TEMP button on one of the 3000 controllers, with the controller in the OFF position, to verify software
version of the ATO. If the version is not visible, the ATO may not be connected properly.
1.13.4 Replacing the ATO Pump
Disconnect the fryer from the electrical power
supply. Locate the ATO pump (see Figure 3), behind
the ATO box. Mark and unplug any wires or
harnesses. Press up from the bottom on the quick
disconnects to release the plumbing (see Figure 4).
The plumbing can be pulled from the pump. Loosen
the four nuts attaching the pump to the pump tray.
Replace the defective component and reverse above
steps. Once replaced, reconnect the power.
Figure 3
Figure 4
1.13.5 Replacing the ATO Solenoids
Disconnect the fryer from the electrical power supply. Locate the top off manifold in the rear of the fryer.
The top off manifold is the smaller of the two manifolds. The solenoids are attached to the manifold (see
Figure 5). Mark and unplug any wires. Replace the defective component and reattach all wires or harnesses.
Once replaced, reconnect the power.
Top off
manifold
Figure 5
Solenoid
1-32
1.13.6 Control Power Reset Switch
The control power reset switch, is a momentary rocker switch located
below the left control box (see Figures 6), that resets all power to all the
controllers and boards in the fryer. It is necessary to reset all power after
replacing any controller or board. Press and hold the switch for at least
ten seconds when resetting the control power to ensure power has
sufficiently drained from boards.
Figure 6
1.13.7 Testing ATO RTD Probes.
The controller features a quick way to compare the temperature of the ATO RTD to the vat temperature. This
is useful for diagnosing ATO issues.
With the controller OFF, press and hold the TEMP button. The controller will display AIF and ----- followed
by ATO and current resistance temperature. Ignore the AIF display. It shows ---- if not installed. Compare
the resistance of the ATO probe against the controller reading. If the values differ greatly a harness issue may
exist.
1.13.8 Replacing ATO Probe
See steps 1.9.2 on page 1-8.
1.14
Controller Service Procedures
1.14.1 Controller Troubleshooting
Problem
No Display on
Controller.
Probable Causes
A.
B.
C.
D.
E.
Controller not turned on.
No power to the fryer.
Controller has failed.
Damaged controller wiring harness.
Power supply component or interface
board has failed.
Controller displays A. Another filtration cycle is still in
filter busy.
process.
1-33
Corrective Action
A. Press the ON/OFF switch to turn
the controller on.
B. Verify controller power cord is
plugged in and that circuit breaker
is not tripped.
C. Swap the controller with a
controller known to be good. If
controller functions, replace the
controller.
D. Swap with a harness known to be
good. If controller functions,
replace the harness.
E. If any component in the power
supply system (including the
transformer and interface board)
fail, power will not be supplied to
the controller and it will not
function.
A. Wait until the previous filtration
cycle ends to start another filtration
cycle. This may take up to one
minute.
If filter busy is still
displayed with no activity, remove
and restore ALL power to the fryer.
Problem
Controller displays
CALL TECH
Controller displays
RECOVERY
FAULT.
Controller displays
SERVICE
REQUIRED followed
by the error.
Controller displays
CHANGE FILTER
PAPER?
Controller display is in
wrong temperature
scale (Fahrenheit or
Celsius).
Controller
displayshot-hi-1.
Controller displays HILIMIT.
Controller displays
low temp
alternating with
temperature.
Controller displays lo
or LOw temp.
Probable Causes
Corrective Action
Typically shown during software update.
Press the FILTER button to bypass and
Also may be that parameter data has been
continue.
corrupted or lost.
Silence the alarm by pressing the 
Recovery time exceeded maximum time
button. Check that fryer is heating
limit for two or more cycles.
properly. Maximum recovery for a gas
fryer is 2:25.
Press YES to silence alarm. The error
is displayed three times. See list of
issues in section 1.14.4. Fix issue. The
controller displays SYSTEM
An error has occurred.
ERROR FIXED? YES/NO.
Press YES. Pressing NO will allow
the fryer to cook but the error will be
redisplayed every 15 minutes.
Daily filter paper change prompt has Press  (YES), follow prompts and
occurred.
change the filter paper.
Frypot temperature is between 180°F
(82°C) and 315°F (157°C).
Fryers using the 3000 controller can
toggle between F° to C° by pressing the
 button until Main Menu changing to
Product setup is displayed. Press  to
scroll to Tech Mode and press . Enter
1658. Press the scan button. The
controller displays OFF. Turn the
controller on to check temperature. If
the desired scale is not displayed,
repeat.
Fryers using the CM3.5 should refer to
the separate Fryer Controllers User’s
Manual.
This in an indication of a malfunction
in the temperature control circuitry,
including a failure of the high-limit
thermostat.
This is displayed only during a test of
the high-limit circuit and indicates that
the high-limit has opened properly.
This display is normal when the fryer is
heating and out of melt cycle until the
temperature reaches ±2° of setpoint.
Frypot temperature has dropped more than
21ºF (12ºC) for CM3.5 or 40°F (17°C) for
3000 controllers below setpoint in idle
mode or 45°F (25°C) in cook mode.
This display is normal for a short while
if a large batch of frozen product is
added to the frypot or if the fryer is not
heating properly.
Incorrect display option programmed.
Frypot temperature is more than 410ºF
(210ºC) or, in CE countries, 395ºF
(202ºC).
Controller in high-limit test mode.
Controller displays
low temp, heating
indicator cycles on and A. Failed controller.
off normally but fryer B. Damaged controller wiring harness.
does not heat.
1-34
A. Replace controller.
B. Replace controller wiring harness.
Problem
Controller displays
CLOSE DRAIN
VALVE.
Controller displays
ERROR RM SDCRD
Controller
displaysTEMP
PROBE FAILURE.
Controller displays
PROBE FAILURE
with alarm sounding.
Controller displays
HEATING
FAILURE.
Probable Causes
Corrective Action
Drain valve is open or switch is out of
adjustment or failed.
Ensure all drain valves are completely
closed and that microswitches are
adjusted and working.
Defective SD Card
Replace card with another card.
Problem with the temperature measuring
circuitry including the probe.
Damaged controller wiring harness or
connector.
Open drain valve, failed controller, failed
interface board, open high-limit
thermostat.
Controller will not go
into program mode or
Failed controller.
some buttons do not
actuate.
Controller displays
low temp, heating A. Failed controller.
indicator cycles on and
off normally but fryer B. Damaged controller wiring harness.
does not heat.
Controller displays Drain valve not fully closed.
HEATING
FAILURE with alarm
sounding. Heating
indicator is on, but
fryer is not heating.
Controller displays
HEATING
FAILURE and alarm
sounds, but fryer Failed controller.
operates normally
(false alarm).
Controller displays HI
2 BAD.
Controller in high-limit test mode.
Controller displays
software for only 3000
or ATO board.
Loose or damaged harness
1-35
This indicates a problem within the
temperature probe circuitry. Check
resistance of probe. If faulty, replace
probe.
Swap the controller wiring harness
with one known to be good. If
problem is corrected replace the
harness.
Is displayed if the fryer loses its ability
to heat oil. It is also displayed when
the oil temperature is above 450°F
(232°C) and the high-limit thermostat
has opened, halting the heating of the
oil.
Replace controller
A. Replace controller.
B. Replace controller wiring
harness.
Ensure all drains are fully closed.
Using the ON/OFF switch, turn the
controller OFF and then ON again.
Replace controller.
This is displayed only during a test of
the high-limit circuit and indicates that
the high-limit has failed.
Check that all harnesses between 3000’s
and ATO are secure and no pins are
pushed out or broken.
1.14.2 3000 Controller Useful Codes
To enter any of the following codes: Press and hold the  button until Main Menu changing to
Product setup is displayed. Press  to scroll to Tech Mode and press TECH MODE
ENTER CODE is displayed. Press the  button. Enter a code number below:

Change Fryer Type, CE/Non-CE, Fresh Oil Setup, Waste Oil Setup and Energy Type –
Enter 7628.

Clear E-Log, Clear Passwords, Change Lane Count, Adjust Max Cook Temp and
Perform High Limit Test, – Enter 3000.

Reset Factory Menu - Enter 3322. The controller display flashes and quickly counts from 1-40
and switches to off. (NOTE: This will delete any hand-entered menu items).

Reset BADCRC Message - Disconnect board locator plug (J3). Reinsert plug. Enter 9988.
Controller display switches to off. Remove and then restore power to the controller using the 20pin plug.

Change from F° to C° - Enter 1658. The controller displays off. Turn the controller on and
check temperature to see the temperature scale. If the desired scale is not displayed, repeat.

Reset RECOVERY FAULT CALL SERVICE – Enter 0042.
PASSWORDS
Product Setup Mode: Press and hold the  button until Main Menu changing to Product
setup is displayed. Press the  button. ENTER CODE is displayed. Enter 1650.
Vat Setup Mode: Press and hold the  button. Main Menu changing to Product setup is
displayed. Press  to scroll to Vat Setup and press . ENTER CODE is displayed. Enter 1656.
Tech Mode: Press and hold the  button until Main Menu changing to Product setup is
displayed. Press  to scroll to Tech Mode and press . TECH MODE is displayed. Press the 
button. ENTER CODE is displayed. Enter 3000 or a code from above.
1.14.3 Service Required Errors
A SERVICE REQUIRED error alternating with YES displays on the controller. After YES is
pressed the alarm is silenced. The controller displays an error message from the list below
three times with the location of the error. Then the controller displays SYSTEM ERROR
FIXED? YES/NO. Press YES if fixed. If NO is chosen the system returns to cook mode for 15
minutes then redisplays error until issue is fixed.
1-36
1.14.4
Error Log Codes
Code
E03
E04
E05
ERROR MESSAGE
ERROR TEMP PROBE FAILURE
HI 2 BAD
HOT HI 1
E06
E08
E17
E20
E21
E22
E25
E27
EXPLANATION
TEMP Probe reading out of range
High limit reading is out of range.
High limit temperature is past 410°F (210°C), or
in CE countries, 395°F (202°C)
HEATING FAILURE
A component has failed in the high limit circuit
such as controller, interface board, contactor or
open-high limit.
ERROR ATO BOARD
ATO board connection lost; ATO board failure
ERROR ATO PROBE
ATO RTD reading out of range
INVALID CODE LOCATION
SD card removed during update
FILTER PAPER PROCEDURE ERROR 25-hour or customer-set timer has expired.
(Change Filter Paper)
OIL IN PAN ERROR
Oil may be present in the filter pan.
RECOVERY FAULT
Recovery time exceeded maximum time limit.
Recovery time should not exceed 1:40 for
electric.
LOW TEMP ALARM
Oil temperature has dropped 40°F (17°C) below
setpoint temperature in idle mode or 45°F (25°C)
in cook mode. (This message may appear if a
product is dropped and the start cook button is
not pressed immediately or if too large of cook
loads are dropped.)
1-37
1.14.5 3000 Controller Menu Summary Tree
Reflected below are the major programming sections in the 3000 and the order in which submenu
headings will be found under the sections in the Installation and Operation Manual.
Adding New Product Menu Items
See section 4.6-4.8
1-38
1.14.6 3000 Controller Pin Positions and Harnesses
Connector
J2
J3
From/To
Interface
Board to
Controller
Locator
Harness
Interface
Board Ground
to Controller
Harness PN
8075165
SMT Controller to
Interface Board
Harness
1080485
1080486
1080487
1080488
1080489
J4
Drain Switch
8075159 (FV)
8075160 (DV)
J6
Previous 3000
J7 or Network
Resistor
8074546
Controller
Communication
Harness
J7
ATO J1 or
Next 3000 J6
8074646
Controller
Communication
Harness
1-39
Pin
#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
1
2
3
4
5
6
Function
12VAC In
Ground
12VAC In
FV Heat Demand
V Relay
DV Heat Demand
R/H B/L
Analog Ground
L/H B/L
ALARM
Sound Device
ALARM
FV Probe
Common Probes
DV Probe
Voltage
12VAC
Blower Relay
12VDC
Vat #1
Vat #2
Vat #3
Vat #4
Vat #5
Wire Color
12VAC
12VDC
12VDC
Orange
12VDC
5VDC
Orange
Black
FV Drain
FV Drain
DV Drain
DV Drain
Ground
CAN Lo
CAN Hi
Black
Red
Black
Red
Black
Red
White
Ground
CAN Lo
CAN Hi
Black
Red
White
1.15
Loading and Updating Software Procedures
Updating the software takes approximately 30 minutes. The software only needs to be loaded in ONE controller or the
far left controller in a battery and it will update all the controllers and boards in the system. Press the TEMP button to
check current 3000 and ATO software version. Remove the bezel by removing the screws under the bottom of the
bezel. Remove the two screws securing the controller allow it to swing down. Remove the two screws on the left side
cover plate of the 3000 controller or far left controller in a battery.
To update the software, follow these steps carefully:
Left Display
Right Display
Action
OFF
OFF
UPGRADE IN
PROGRESS
CC
UPDATING
BOOT
WAIT
With the controller folded down, insert the SD card, with the contacts facing
down and the notch on the bottom right (see Figure 7 and 8), into the slot on the
left side of the 3000 controller. ENSURE THE CARD IS FULLY
INSERTED INTO THE SD CARD SLOT.
None required.
PERCENTAGE
COMPLETE
BLANK
CALL
TECH
UPGRADE IN
PROGRESS
IF_COOK
HEXand
IF_aTO HEX
REMOVE SD
CARD
CYCLE
POWER.
BOARD ID
WAIT
System
type
System
type
TYPE
PERCENTAGE
COMPLETE
100
BLANK
Zero or a number
from 1-4
OCF30
OCF30
None required.
None required.
If this message is displayed, press the FILTER button and the software load will
continue.
None required.
None required.
Remove the SD card using the fingernail slot on the top of the SD card.
Cycle the control power using the hidden reset switch under the far left control
box. ENSURE THE SWITCH IS HELD FOR 10 SECONDS.
Press the IO (Power) button.
Press the or  to choose correct fryer type. OCF30 (Frymaster)
Press . Ensure correct fryer type is displayed.
TYPE
GL30
Press the or  to select proper fryer model. One of several fryer models may
be displayed.
Once proper fryer model is displayed, press .
EXIT
EXIT
Press the  (check) button.
OFF
OFF
OFF
OFF
OFF
OFF
With the controller displaying OFF, VERIFY software update by pressing
the TEMP button to check updated 3000 version on each controller. 3000
should display software version 40.0159.03 for 3000 and 35.0157.00 for ATO.
Once the software has been updated and the versions are correct, replace the
cover and screws covering the SD card slot. Replace the screws attaching the
controller and replace the bezel and screws.
Using the instruction sheet 819-6806, perform tech mode setup and vat setup.
OFF
OFF
Set the current date and time using instructions 819-6806.
GL30
1-40 Figure 7
Figure 8
1.16
Principal Wiring Connections
1-41
1.17
Wiring Diagrams
1.17.1 FPGL230/430 Wiring
1-42
1.17.2
FPGL330 Wiring
1-43
1.17.3
FPGL430 Extra Transformer Box Wiring
1-44
1.17.4
Modular Basket Lift (100/120V)
1-45
1.17.5
Modular Basket Lift (208/250V)
1-46
1.17.6
Basket Lift Interface Harness
1-47
1.18 Simplified Wiring Diagrams
1.18.1 FPGL30 Series Full Vat with Dual Spark Module
1-48
1.18.2
FPGL30 Series Full Vat Single Spark Module
1-49
1-50
LEFT
IGNITOR
HV
TD
GND
BNR
VALVE
GND
25V+
ALARM
LEFT IGNITION
MODULE
AIR SWITCH ONLY
ON CE AND SOME
EXPORT UNITS
2
ALARM
V2D
L
PWR
J1
DRAIN SAFETY SWITCH
ONLY ON UNITS WITH
BUILT-IN FILTRATION
M
T
HEAT
LHEAT
LED 2
12
6
14
15
1K
47K
1/50
4
TROUBLE
12
6
14
K1
HEAT
RELAY
15
6
TEMP
PROBE
LINE
VOLTAGE
HOOD
RELAY
A
8
LED 1
L-GV
9
HIGH
LIMIT
GV
2
2
5
ON/OFF
POWER
SWITCH
(OPT) DRAIN SAFETY
3
3
1
LED 6
12V
3
1
1
12V
GV
AIR
LED 3
24V
F2
FUSE
8
24V
ON/OFF
POWER
5
5
TROUBLE
10
10
1K
47K
1/50
4
A
4
4
13
13
14
12
F1
FUSE
M
T
2
BLOWER
14
11
K2
HEAT
RELAY
OPTIONAL
AIR
SWITCH
AIR LED not
applicable to fryers
manufactured before
6/96
LED 5
R-GV
9
HIGH
LIMIT
SWITCH
(OPT) DRAIN SAFETY
FPGL30 SERIES – DUAL VAT
HEAT
RHEAT
LED 4
11
11
6
J3
J2
V1D
ALARM
R
PWR
TEMP
PROBE
SD
H
V
TD
RIGHT
IGNITOR
‘
PROBE CIRCUIT
12
VAC
24
VAC
SOUND DEVICE CIRCUIT
12 VDC
LINE VOLTAGE
BNR
GND
VALVE
GND
25V+
ALARM
RIGHT IGNITION
MODULE
F1 Fuse not
applicable to
fryers
manufactured
before 6/96
1.18.3
FPGL30 Series Dual Vat Single Spark Module
1.18.4 FPGL30 Series Simplified Wiring with 3000 Controller
1-51
1.18.5 FPGL30 Series Data Network Flowchart
1-52
1.18.6 Shortening Melting Unit Wiring Diagram
1-53
1.18.7 Bulk Oil Wiring Diagram
805-1927B
1-54
1.18.8 Bulk Oil Box Wiring
1-55
OCF™ SERIES GAS FRYERS
CHAPTER 2: PARTS LIST
2.1
ITEM
1
Accessories
PART #
230-8165
230-7495
230-7497
2
803-0197
3
803-0398
4
230-2975
5
106-8930
*
826-0993SP
6
803-0099
7
803-0271
8
803-0382
9
803-0375
10
810-0478
806-1698SP
806-1699
11
810-0074
12
810-0073
13
826-0900
14
826-1045
15
810-0070
810-0073
*
803-0170
*
803-0002
*
823-8066
*
823-8224
* Not illustrated.
COMPONENT
Hanger, Basket Single
Hanger, Basket Two Station (use two for a Four Station fryer)
Hanger, Basket Three Station
Cleanout Rod, 27-inch
Brush, Frypot
Connecting Strip, Frypot (use 230-4677 for Spreader Connecting Strip)
Cover, Full-Vat Frypot (use 106-8931 for Dual-Vat Cover)
Handle Kit, Frypot Cover (includes handle and screws)
Basket, Full Size
Basket, Twin Size
Sediment Tray, Full Vat
Rack, Full-Vat Basket Support (use 803-0372 for Dual-Vat Basket Support)
Gas Line, 1-Inch Dormont Flexible
36-Inch (for gas line only (w/o Items 11 and 12), use 810-0088)
48-Inch (for gas line only (w/o Items 11 and 12), use 810-0085)
Quick-Disconnect Fitting, 1-Inch Male
Quick-Disconnect Fitting, 1-Inch Female
Kit, Chain Restraint
Bushing, Flexible Gas Line (813-0032)
Coupling, Gas Line Female Quick Disconnect ¾-inch
Coupling, Gas Line Female Quick Disconnect 1-inch
Pack, 100-Sheet Filter Paper 19.5X 27.5
Powder, Filter (80- 1-Cup Applications)
Plate, Fish
Shield, Splash Frypot
2-1
2.2 Basket Lift Assy and Associated Parts
2-2
2.2 Basket Lift Assy and Associated Parts cont.
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
*
*
PART #
106-1808SP
106-1805SP
106-1806SP
810-1012
813-0035
807-2513
901-8499
902-8499
807-0159
900-5529
812-0442
807-2572
806-5964SP
200-2942
807-1683
806-8530SP
106-2770SP
106-2771SP
809-0082
910-4776
809-0127
823-8015
823-8016
810-0179
108-2743SP
108-2860
810-0194
810-0374
809-0508
823-7980
823-8023
809-0990
824-1477
824-1476
*
108-3454
*
807-3695
*
WIR-0166SP
*
106-1822SP
*
106-1804SP
* Not illustrated.
COMPONENT
Basket Lift Assemblies (see Note 1 in illustration)
Basket Lift Assy, 100-120VAC w/Relay (Items 1-20) shown
Basket Lift Assy, 200-220VAC w/Relay (Items 1-20) shown
Basket Lift Assy, 230-250VAC w/Relay (Items 1-20) not shown
Rod, Basket Lift
Bushing, Bronze
Capacitor, 12.5 μFd 330VAC
Chassis, Left Basket Lift
Chassis, Right Basket Lift
Connector, 12-Pin Female
Gusset, Basket Lift Motor
Insulation, Microswitch
Microswitch
Motor Assy, 208-240VAC Modular Basket Lift
Mount, Modular Basket Lift
Relay, 12VDC
Resistor Assy
100-120V Modular Basket Lift (see Note 2 in illustration)
208-220VAC Modular Basket Lift
230-250VAC Modular Basket Lift
Ring, Bushing Retainer
Cover, Modular Basket Lift Rear S/S (Use 900-4776 for Mild Steel)
Screw, ¼-20 X ½-inch Slotted Round Head
Arm, Left Basket Lift
Arm, Right Basket Lift
Button, Plug
Roller Assy, Basket Lift
Mount, Basket Lift Roller
Roller, Basket Lift
Spacer, Basket Lift Roller
Bolt, ¼-20 X 1¼ -Inch
Guide, Basket lift Left
Guide, Basket lift Right
Nut, ¼-20 Cap
Tray, Drip Right
Tray, Drip Left
Wire Assemblies
Harness, Gas OCF BL Interface
Basket Lift Cable
Wire Bundle, 200-250VAC Basket Lift w/Relay
For 100-120V Modular Basket Lift
For 208-250V Modular Basket Lift
2-3
2.3 Doors, Sides, Flue Caps, Top Caps and Casters
1
2
6
7
3
5
8
4
10
9
ITEM
1
2
3
4
5
6
*
*
*
*
*
7
8
9
PART #
231-7908
232-7908
810-1105
106-4397
230-4960
106-4067
810-0275
809-0970
230-7192
210-8288
220-6097
810-0327
810-0944
823-7962
823-7724
823-7727
823-7728
10
108-2691
108-1522
108-1523
108-1524
* Not illustrated.
COMPONENT
Side, Standard Cabinet Left SS
Side, Standard Cabinet Right SS
Magnet, Door (vertical) (use 810-2346 for horizontal over filter pan)
Door, Left or Right (Left shown – move handle to bottom for right)
Handle, Eurolook Door
Pin Assy, Door
Spring, Door Pin
Retaining Ring
Hinge, Door Lower
Panel, Universal Door
Holder, Manual
Caster 4” without Brake
Caster 3” with Brake
Flue Cap-Stainless Steel
Single Station Fryer
Two Station Fryer
Three Station Fryer
Four Station Fryer
Top Cap
Single Station Fryer
Two Station Fryer
Three Station Fryer
Four Station Fryer
2-4
2.4
Drain System Components
2.4.1 Drain Valves and Associated Parts
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
*
*
PART #
108-3181
108-2509
108-3182
108-2507
108-2593
108-2449
108-3323
108-3324
108-2451
809-0540
900-2936
230-8556
230-8557
824-2188
824-2189
814-0047
901-2348
807-4936
816-0220
200-6496
108-2506
108-2537
220-8162
816-0135
810-1018
810-1569
812-1226
807-5159
807-5160
COMPONENT
Valve, Assy Drain FV with Filter and Auto Top Off
Valve, Assy Drain DV Left with Filter and Auto Top Off (use 108-2510 for Right)
Valve, Assy Drain FV with Filter (No Top Off)
Valve, Assy Drain DV Left with Filter ( No Top Off) (use 108-2508 for Right)
Valve, Assy Drain FV Single with Filter (No Top Off)
Valve, Assy Drain DV Left Single with Filter (No Top Off) (use 108-2450 for Right)
Valve, Assy Drain DV Right Long Handle with Filter (No-Top Off)
Valve, Assy Drain DV Right Long Handle with Filter and Auto Top Off
Valve, Assy Drain DV Left/FV Long Handle with Filter and Auto Top Off
Nut, ½-13 2-Way Hex Lock
Retainer, Nut Drain Valve
Handle, Drain Valve FV with Filter
Handle, Drain Valve DV Left with Filter (use 230-8558 for Right)
Handle, Drain Valve Long FV Single and DV Left with Filter & auto top off
Handle, Drain Valve Long DV Single Right and DV Left With Filter
Cap, Vinyl Red
Cover, Safety Switch
Switch, Micro Gold Plated
Insulation, RF Switch
Support, Drain Tube
Bracket Assy, Drain Switch FV and DV Left
Bracket Assy, Drain Switch DV Right
Bracket, Single 1¼-inch Drain Valve (used on FV Single with Filter)
O-Ring, Round Drain Seal
Valve, 1¼-inch Drain with Filter
Valve, 1¼-inch Drain Non-Filter
Drain Extension 1¼-inch (use with 810-1569)
Harness, Drain FV (connects from drain switch to rear of 3000 controller only)
Harness, Drain DV(connects from drain switch to rear of 3000 controller only)
2.4.2 Drain Tube Sections and Associated Parts
2-5
See Section 2.4.1 for Drain Valves
2-6
2.4.2 Drain Tube Sections and Associated Parts cont.
ITEM
1
2
3
PART#
823-8135
823-8136
823-8137
823-7959
4
823-8138
823-7946
5
823-8139
*
823-8130
6
823-7943
*
823-8131
7
823-4643
8
823-7905
9
810-3550
10
810-3551
11
823-4625
12
823-7906
13
823-4639
14
823-7908
15
823-4641
16
823-7907
17
816-0772
18
809-0969
*
816-0630
*
811-1071
19
823-7915
* Not illustrated.
COMPONENT
Drain Tube, Dump Full-Vat Left Closed/Right End Open
Drain Tube, Dump Dual-Vat Left Closed/Right End Open
Drain Tube, Dump Full-Vat Left Closed Both Ends
Drain Tube, Dump Single Full-Vat Left Closed Both Ends
Drain Tube, Dump Dual-Vat Left Closed Both Ends
Drain Tube, Dump Single Dual-Vat Left Closed Both Ends
Drain Tube, Dump Full-Vat Left Closed Both Ends
Drain Tube, Dump Full-Vat Left Closed/Right End Open
Drain Tube, Dump Dual-Vat Left Closed Both Ends
Drain Tube, Dump Dual-Vat Left Closed/Right End Open
Drain Tube, Full-Vat, Short, Open Both Ends
Drain Tube, Dual-Vat, Short, Open Both Ends
Drain Tube, Short, Open Both Ends
Drain Tube, Long, Open Both Ends
Drain Tube, Short Full-Vat Left Open/Right End Closed
Drain Tube, Short Dual-Vat Left Open/Right End Closed
Drain Tube, Long Full-Vat Left Open/Right End Closed
Drain Tube, Long Dual-Vat Left Open/Right End Closed
Drain Tube, Long Full-Vat Open Both Ends
Drain Tube, Long Dual-Vat Open Both Ends
Sleeve
Clamp
Vinyl Cap
Tubing, ¼-inch OD Teflon Vent (sold by the foot)
Guard, Filter Lid Splash
2.5
Electronics and Electrical Components
2.5.1 Controllers and Associated Components
NOTE: See Page 2-20 for Interface Board to Controller Wiring Harness
ITEM
√ 1
√ 2
PART #
108-2399SP
826-2380
826-2381
826-2382
810-3141
√ Recommended parts.
COMPONENT
Replacement 3000 Controller
Replacement CM 3.5 Controller
Non-CE CM3.5 (For use in US, Canada, Mexico and all other non-CE countries)
CE CM3.5 (For use in European CE countries)
CE CM3.5 (For use in non-CE countries with 8 sec. melt cycle)
Sound Device, Universal SMT
2-7
2.5.2 Component Boxes
2-8
2.5.2 Component Boxes cont.
ITEM
1
2
√ 3
√ *
*
√ 4
*
*
5
*
6
7
√ 8
√ 9
√ 10
√
√ 11
PART #
810-1164
816-0217
807-3843
826-1157
807-3293
106-0531SP
807-5008
807-5009
807-3484
807-4199
807-5165
806-6085SP
220-6102
807-2971
807-1006
807-3366†
807-3365†
826-2264
807-4330
807-4343
√ 12
807-0833
√ 13
807-0834
14
810-2243
15
108-1094
16
824-2090
17
824-2091
18
220-7085
19
108-1544
20
807-1683
21
106-0531SP
*
807-2659
*
807-4403
22
108-1260
108-2353
23
806-4973
24
108-2581
* Not illustrated.
√ Recommended parts.
COMPONENT
Block, One-Piece Screwless Terminal
Insulation, Terminal Block Paper
Fuse 3A 250V Domestic
Kit, Fuse and Fuse Puller (2 Fuses)
Fuse 5A 125V International Only
Fuse Assy, Inline
Cable, 21-inch Ignition – For 807-3366/807-3365 Modules
Cable, Ignition 19” (CE)
Connector, Rajah
Cable, 20-pin Controller to 15-pin Interface Board – SMT for fryer’s with CM 3.5
controller.
Cable, 20-pin Controller to 15-pin Interface Board – SMT for fryer’s with 3000 controller.
Wire Assembly, Ignitor
Box, One-Piece Component
Ignition Module, (Australia)
Ignition Module, CE
Ignition Module, Dual-Spark Full-Vat (Domestic and Non-CE export unit except
Australia)
Ignition Module, Single-Spark Dual-Vat (Domestic and Non-CE export unit except
Australia)
Interface Board Kit SMT
Speaker Adapter Harness SMT
Wire Harness, SMT Interface Board to Ignition Module
Relay, DPDT 5A 12VDC Latch (See NOTE 1.)
Relay, SPDT 15A 12VDC Basket Lift (See NOTE 2.)
Spring, Relay Retaining
Plate, Ignition Module
Cover, Ignition Module
Cover, Ignition Module CE
Cover, Ignition Module Australia
Plate, Ignition Module Australia
Relay, 12VDC Secondary Blower Fan to cool frypot
Fuse Assembly, Inline (not used on all models)
Switch, Momentary (Control Power Reset, only used in far left component box)
Speaker SMT
Wire Assembly, Ignition Module Domestic and Non-CE export, except Australia.
Wire Assembly, Ignition Module CE
Interface Board, Australia
Harness, Secondary Blower
† For Full-vat units, use one 807-3366 Dual Spark Ignition Module (see NOTE 1).
† For Dual-vat units, use two 807-3365 Single Spark Ignition Modules (see NOTE 1).
NOTE 1: U.S., Canadian, and Mexican units use two different modules depending upon the configuration of the frypot.
Full-Vat units use one 807-3366 Dual-Spark Ignition Module while Dual-Vat units use two 807-3365 Single-Spark Ignition Modules. Also, in full-vat units, only two latch relays (Item 12) are used, located in the sockets on the right side of
the interface board. These relays are located in the bottom sockets of the interface board and control the heating circuit.
NOTE 2: The relays in the top sockets control the basket lifts (Item 13) and are present only on units equipped with
basket lifts.
2-9
2.5.3 Transformer Boxes
ITEM
PART #
A
106-9021
B
106-9022SP
C
108-1765
D
108-1764
E
108-1768
√ 1
807-2176
√ 2
807-0800
√ 3
807-2180
√ 4
807-5129
5
220-6514
√ Recommended parts.
COMPONENT
Box Assembly, Transformer
GL230 and 430 (430 has added cordset 108-1769)
GL330
GL230 and 430 CE and Export (430 has added cordset 108-1770)
GL330 CE and Export
GL430 CE and Export
Transformer, 100-120V V/F Dual Voltage
Transformer, 100-120V/24V 50VA Filter and MIB
Transformer, 100-120VV/24V 50VA Filter and MIB
Transformer, V&F Dual Voltage 208/222/230/240V
Cover, GL30 Small Transformer Box
2-10
2.5.3 Transformer Boxes cont.
ITEM
√ 6
PART #
807-4346
√
√ 7
8
9
√ 10
11
12
13
14
15
807-4770
807-0012
816-0217
810-1164
807-1597
807-1973
807-0070
220-3191
823-6324
108-1728
16
106-8168
17
106-8170
18
108-0994
19
108-0995
20
108-0996
21
108-1778
22
108-1777
23
108-1789
24
823-7638
*
WIR 0798
*
WIR 0957
*
WIR 0958
*
108-3433
*
108-3432
* Not illustrated
√ Recommended parts.
COMPONENT
Relay, DPDT 20A 120VAC (Control Reset Button) (used for control power reset in
domestic units)
Relay, DPDT 20A 240V (used for control power reset in international units)
Relay, Filter 18A 24VAC
Insulation, Terminal Block Paper
Block, One-Piece Screwless Terminal
Fuse, 3amp Slo-Blow
Terminal, Post
Terminal, Ground Lug
Cover, Large Transformer Box
Box, Large Transformer/Filter
Cable Assembly, Transformer Box Line GL230, 330, 430, 230 and 330 CE Export
and 430 CE Export Filter Pump
Cable Assembly, Transformer Box Line GL230 CE Export
Cable Assembly, Transformer Box Filter Pump GL230, 330, 230 and 330 CE Export
Cable Assembly, Transformer Box #1 GL230,330, 230 and 330 CE Export
Cable Assembly, Transformer Box #2 GL230, 330, 230 and 330 CE Export
Cable Assembly, Transformer Box #3 GL330 and 330 CE Export
Harness Assembly, Vat # 4
Harness Assembly, Vat # 3
Harness Assembly, 4 Batt Cordset
Box, Transformer/Filter GL30 4-Battery
Wire Assembly, GL230/330 Transformer/Filter Box (used in Items A, B, C and D)
Wire Assembly, GL230/430 (used in Items A, B, C and D)
Wire Assembly, GL 430 (used in Item E)
Harness, Bulk Oil Jumper
Harness, T-Box Gas OCF
2-11
2.6
Wiring
2.6.1 Main Wiring Harnesses
2-PIN FEMALE
CONNECTOR
12-PIN MALE
CONNECTOR
9-PIN MALE
CONNECTOR
807-1978
12-PIN MALE
CONNECTOR
2-PIN FEMALE
CONNECTOR
12-PIN MALE
CONNECTOR
6-PIN MALE
CONNECTOR
807-4014
12-PIN MALE
CONNECTOR
ITEM
PART #
807-1978
807-4014
COMPONENT
Main Wiring Harness 250/450
Main Wiring Harness 350
2-12
2.6.2 3000 and ATO Wiring Harnesses (Refer to wiring diagram on page 1-50.)
ITEM
*
*
*
*
*
*
PART #
807-4546
807-4646
807-4655
826-2569
807-4553
807-5163
*
807-4719
*
807-5161
*
807-5162
*
807-4573
*
807-4552
COMPONENT
Controller Communication (used from controller to controller)
Controller Communication (used from right controller to ATO box)
Harness RTD Medium (used from ATO RTD to ATO Board)
FV/DV ATO/RTD Probe Kit
ATO Power (used from transformer to ATO board #1)
ATO Power ATO Secondary Box (used from transformer to ATO board #2)
ATO Pump and JIB (used from ATO Board to Top-off Pump and JIB Reset
Switch)
Harness, ATO Solenoid, Pump Relay Primary (used from ATO Board to Top-off
Pump Relay, Solenoids, and JIB Reset Switch)
Harness, Secondary ATO Solenoid, Pump Relay (used in second ATO box on 4
battery fryers from ATO Board to Top-off Pump Relay and Solenoids)
Controller Locator Wire (used from controller to interface board) See wiring diagram 805-1855 on page 1-51 for locator pin positions.
Communications Terminator (used on controller pin J6 and ATO board pin J10 to
terminate network)
Jumper (used on 4 and 5 battery ATO board plug J5 pin 7 and 8)
Long Top-off Power (used between ATO box #1 and #2)
SMT Pin Service Repair Kit
SMT Pin Extractor
807-4657
*
106-9544
√ *
807-4660PK
√ *
230-2345
* Not illustrated.
√ Recommended parts.
See page 1-30 and 1-39 for Pin Positions.
2-13
Kit 826-2592 contains the
insulation and gaskets required when replacing
burners.
NOTE: All insulation and
gaskets can be ordered in
a single kit, P/N 826-2595.
2.7
Frypots and Associated Components
2.7.1 Full-Vat Frypot Components
2-14
2.7.1 Full-Vat Frypot Components cont.
ITEM
PART #
108-2222SP
108-2224
108-2849
108-2848
826-2595
826-2592
1
108-2897
2
220-6470
3
220-6529
4
220-7831
5
230-6960
6
220-2851
7
220-2920
√ 8
810-3435
9
812-0356
10
816-0900
11
812-0706
12
812-1029
13
814-0048SP
14
816-0837
15
816-0731
16
816-0732
17
816-0733
18
816-0839
19
816-0746
20
823-7824
823-8022
21
823-7454
22
823-7455
23
823-7279
24
823-7415
25
824-2164
26
824-2165
27
900-1031
28
930-0818
29
900-4253
30
900-1049
31
816-0057
32
823-6660
*
816-0059
* Not illustrated.
√ Recommended parts.
COMPONENT
Frypot Assy Full-Vat OCF with filter (NAT)
Frypot Assy Full-Vat OCF with filter (PRO)
Frypot Assy Full-Vat OCF non-filter (NAT)
Frypot Assy Full-Vat OCF non-filter (PRO)
Insulation Kit, Complete Full-Vat
Insulation Kit, Burner Full-Vat
Flue Assembly, Full-Vat
Back, Lower Full-Vat Combustion Chamber
Retainer, Full-Vat Upper Insulation
Retainer, Outer Frypot
Plate, FV Collector Mounting
Brace, FV Rear Insulation
Brace, Foam Deck Insulation
Burner, Universal Replacement
Insulation, Burner Sight Glass
Insulation, Burner
Insulation, Upper Burner Rail
Insulation, Combustion Chamber Side
Glass, Burner Sight
Insulation, FV Rear Lower
Insulation, FV LH/RH Front Seal
Insulation, FV Lower Inner Front
Insulation, FV Front Upper
Insulation, FV Outer Front
Insulation, Foam Deck
Frypot, FV OCF with filter
Frypot, FV OCF without filter
Retainer, FV LH Upper Burner
Retainer, FV RH Upper Burner
Retainer, FV Front Insulation
Retainer, FV Outer Front
Front Upper Seal Weldment, FV LH
Front Upper Seal Weldment, FV RH
Retainer, Burner Sight Glass
Bracket, Flue to Pot
Strip, Fluecap Retainer
Retainer, Plenum Gasket
Gasket, Plenum
Plenum, Full-Vat (use 823-7720 for CE units)
Gasket, Ignitor
2-15
33
2-16
24
3
17
6
19
Kit 826-2593 contains the
insulation and gaskets
required when replacing
burners.
NOTE: All insulation and
gaskets can be ordered
in a single kit, P/N 8262596.
32
31
28
18
9
13
23
4
26
12
16
22
27
34
25
8
15
30
11
14
10
20
2
29
12
21
5
7
4
1
2.7.2 Dual-Vat Frypot Components
2.7.2 Dual-Vat Frypot Components cont.
ITEM
PART #
108-2223SP
108-2225
108-2845
108-2844
*
826-2596
*
826-2593
1
108-2898
2
106-7960
3
220-6530
4
220-7916
5
220-6180
6
220-2920
7
220-2972
√ 8
810-3435
9
812-0356
10
816-0900
11
812-0706
12
812-1029
13
814-0048SP
14
816-0838
15
816-0741
16
816-0742
17
816-0743
18
816-0840
19
816-0746
20
812-0688
21
823-7457
22
823-7456
23
823-7416
24
823-7417
25
824-1796
26
824-2166
27
824-2167
28
900-1031
29
930-0818
30
900-4253
31
900-1049
32
816-0057
*
816-0059
33
823-6659
34
823-7862
823-8020
* Not illustrated.
√ Recommended parts.
COMPONENT
Frypot Assy Dual-Vat OCF with filter (NAT)
Frypot Assy Dual-Vat OCF with filter (PRO)
Frypot Assy Dual-Vat OCF non-filter (NAT)
Frypot Assy Dual-Vat OCF non-filter (PRO)
Insulation Kit, Complete Dual-Vat
Insulation Kit, Burner Dual-Vat
Flue Assembly, Dual-Vat
Plate Assembly, Dual-Vat Collector
Retainer, Dual-Vat Upper Insulation
Retainer, Dual-Vat Outer Frypot
Back, Dual-Vat Lower Combustion Chamber
Brace, Foam Deck Insulation
Brace, Dual-Vat Rear Insulation
Burner, Universal Replacement
Insulation, Burner Sight Glass
Insulation, Burner
Insulation, Upper Burner Rail
Insulation, Combustion Chamber Side
Glass, Burner Sight
Insulation, Dual-Vat Rear Lower
Insulation, Dual-Vat LH/RH Front Seal
Insulation, Dual-Vat Lower Inner Front
Insulation, Dual-Vat Front Upper
Insulation, Dual-Vat Outer Front
Insulation, Foam Deck
Insulation, Flue Collection
Retainer, Dual-Vat RH Upper Burner
Retainer, Dual-Vat LH Upper Burner
Retainer, Dual-Vat Front Insulation
Retainer, Dual-Vat Outer Front
Riser W/A Dual-Vat Pot
Dual-Vat LH Upper W/A Seal
Dual-Vat RH Upper W/A Seal
Retainer, Burner Sight Glass
Bracket, Flue to Pot
Strip, Fluecap Retainer
Retainer, Plenum Gasket
Gasket, Plenum
Gasket, Ignitor
Plenum, Dual-Vat (use 823-6939 for CE units)
Frypot, Dual-Vat OCF with filter
Frypot, Dual-Vat OCF without filter
2-17
2.7.3 Frypot Probes and Thermostats
See page 2-5 for Drain Valve Assemblies and page 2-14 through
2-17 for Frypot Assemblies
ITEM
PART #
1
826-2706
2
807-4817
826-1177
3
* Not illustrated.
COMPONENT
Probe, RTD ATO Kit
Probe, Temperature Cooking
Thermostat, High-Limit 425F/218C
2-18
2.8
Gas Valves, Supply and Combustion System Components
See pages 2-13 through 2-15
for burners and burner insulation part numbers.
ITEM
√ 1
PART #
826-0981
826-2994
√ 2
3
*
106-2997SP
108-3307
106-2998SP
106-3001SP
816-0554
806-8806SP
COMPONENT
Ignitor
Natural Gas (G20, G25)
Propane (G30, G31)
Blower Assembly, Combustion Air (includes harness and Item 3)
115V 50/60 Hz (Right)
220V 60 Hz (Right)
208-240V 50/60 Hz (Right) Non-CE International
230V 50/60 Hz CE (Right) CE (Wide Body)
Cover, Blower Motor (component of all blowers listed above)
Harness Assembly, Blower Motor (component of all blowers listed above)
2-19
2.8
Gas Valves, Supply and Combustion System Components cont.
ITEM
4
**
**
**
**
**
**
**
**
√ 5
√ 6
PART #
810-3977
810-3865
810-3860
810-3863
810-3867
810-3866
810-3864
810-3861
810-3862
108-1455
826-1122
826-1120
826-1123
826-1121
√ 7
810-1715
8
810-1041
9
810-0691
10
806-9678SP
11
813-0304
12
813-0700
13
813-0302
14
813-0449
15
810-3147
16
813-0340
17
810-3807
18
813-0154
19
813-0378
20
813-0354
21
810-1026
22
810-1025
23
813-0495
24
810-1006
25
810-1176
26
813-0301
27
810-1353
28
810-1355
*
826-2965
*
826-2966
*
826-2967
*
826-2968
*
826-2969
*
826-2970
*
826-2971
*
826-2972
* Not illustrated.
√ Recommended parts.
COMPONENT
Orifice, Burner
1.88mm 75% Butane/25% Butane (Standard Elevation)
1.95mm Propane/Butane (G30, G31) Australia Only
2.05 mm Propane/Butane (G30, G31) (0-4999 Ft, 0-1524 M)
2.10 mm Propane/Butane (G30, G31) (5000-6999 Ft, 1525-2133 M)
2.84mm Natural Gas (G20, G25) Australia Only DV
2.92mm Natural Gas (G20, G25) Australia Only FV
3.18 mm Natural Gas (G20, G25) (0-4999 Ft, 0-1524 M) CE
3.26 mm Natural Gas (G20, G25) (0-4999 Ft, 0-1524 M)
3.40 mm Natural Gas (G20, G25) (5000-6999 Ft, 1525-2133 M)
Switch, Air Pressure Assembly (807-2141 switch alone)
Valve, Non-CE Gas
Natural Gas (G20, G25)
Kit Natural Gas w/ flexlines and hardware
Propane Gas (G30, G31)
Kit, Propane Gas w/ flexlines and hardware
Valve, CE Gas (G20, G25, G30, G31)
Accessory Kit (contains parts to adapt Item 7 to specific fryer configuration)
Tube, ⅛-inch Vent
Plug Assy, CE Gas Valve
Bushing, ½-inch NPT to ¼-inch NPT Flush Reducing
Nipple, ¼-inch NPT x 3-inch
Elbow, ¼-inch Male NPT to ⅜-inch Tube 90° (used on DV valve)
Tee, ¼ -inch NPT Brass
Bushing, ¾-inch OD x ½ -inch ID NPT Flush
Adapter, ⅛-inch NPT to ⅛-inch Tube
Tube, ⅛-inch OD X 6.5-inch Enrichment
Plug, ⅛-inch NPT Hex Head Pipe
Fitting, ⅛-inch NPT Cross
Elbow, ⅛-inch NPT X ⅛-inch Tube Compression
Tee, ¼-inch Male NPT to Female NPT Street
Connector, ¼-inch Male NPT to ⅜-inch Tube
Tee, ¼-inch Male NPT to Female NPT
Bushing, ¼-inch NPT to ⅛-inch NPT Reducing
Tap, ⅛-inch NPT Pressure
Tee, ¼-inch Male NPT to ⅜-inch Tube
Gas Line, ⅜-inch OD X 9-inch SS Flexible (Used on some split pots)
Gas Line, ⅜-inch OD X 15-inch SS Flexible
Conversion Kit, Natural Gas FV (G20, G25) to Propane/Butane(G30,G31)
Conversion Kit, Natural Gas DV (G20, G25) to Propane/Butane(G30,G31)
Conversion Kit, Propane/Butane FV(G30, G31) to Natural Gas (G20,G25)
Conversion Kit, Propane/Butane DV(G30, G31) to Natural Gas (G20,G25)
Conversion Kit, Natural Gas FV (G20, G25) to Prop/Butane(G30,G31) Aust /CE
Conversion Kit, Natural Gas DV (G20, G25) to Prop/Butane(G30,G31) Aust/CE
Conversion Kit, Prop/Butane FV(G30, G31) to Natural Gas (G20,G25) Aust /CE
Conversion Kit, Prop/Butane DV(G30, G31) to Natural Gas (G20,G25) Aust/CE
2-20
2.9
Filtration System Components
1
2
3
7
8
4
10
9
5
11
6
ITEM
1
2
3
4
5
PART #
823-8028
810-3288
810-3289
812-2025
108-2880
806-9255
813-0568
√ *
826-1392
6
823-6458
823-5591
7
810-1067
8
230-8373
9
230-8372
10
823-8030
11
220-8368
* Not illustrated.
√ Recommended parts.
COMPONENT
Lid, Filter Pan (use 823-7976 for Single Fryer Lid)
Crumb Tray
Hold-Down Ring 11.20 x 19.10,
SanaGrid Filter Screen
Pan, Filter
Pan, Filter Single Fryer
Plug, ⅛-inch Socket Head Pipe (used with Item 5; two required)
O-Ring (Pkg. of 5; used with Item 5)
Suction Tube Assembly
Suction Tube Assembly (Single Fryer Only)
Flexline, 8.50-inch Oil Return
Rail, Upper Filter Pan Left/Right
Rail, Lower Filter Pan Left/Right
Support, Left Filter Pan
Support, Right Filter Pan 3,4 and 5 battery (use 108-2872 for 2 battery)
2-21
2.10
ITEM
1
Filter Pump, Motor and Associated Components
PART #
826-1785
826-1712
826-1756
826-1270
826-1755
2
826-1264
816-0093
3
809-0514
*
807-11973
*
108-0649
*
106-5912
4
106-3470
5
813-0265
6
810-1057
7
810-1067
8
810-1668
9
810-1669
10
813-0165
11
813-0304
12
813-0530
13
813-0838
14
220-6191
*
106-1020
* Not illustrated.
√ Recommended parts.
√
√
COMPONENT
Motor and Gasket Kit
100V 50/60 Hz
115V 50/60 Hz
208V 50/60 Hz
220-240V 50/60 Hz
250V 50/60 Hz
Pump and Gasket Kit, Viking 4 GPM (includes gasket and cap screws below)
Gasket, Pump/Motor
Cap Screw, 5/16-inch-18 4.50” NC Hex (Connects pump to motor.)
Viking Pump Seal Kit
Heater Strip Assembly, 100-120V 25W 18”
Heater Strip Assembly, 208-250V 25W 18”
Valve, Solenoid ¼-inch” NPT
Nipple, ½-inch x 2.50-inch NPT BM
Flexline, 13-inch Oil Return
Flexline, 8.5-inch Oil Return
Adapter, ⅝-inch to ½-inch NPT Male
Adaptor, Female ⅞-inch OD x ½-inch
Elbow, ST ½-inch x ½-inch NPT 90° BM
Bushing, ½-inch x ¼-inch BM Flush
Tee, Reducing ½-inch x ¼-inch x½-inch
Nipple, ¼-inch NPT BM Close
Brace
Wiring, Pump
2-22
2.11 Frypot Assemblies and Associated Parts
Dual Vat
Full Vat
2
1
19
14
4
20
21
9
6
5
To Return
Manifold
8
17
To Top-Off
Manifold
16
18
3
11
11
12
15
14
4
7
17
9
ITEM
PART #
1
823-7824
823-7862
2
*
824-1796
3
810-0667
4
813-0165
5
901-2772
6
902-2772
*
900-2935
7
810-2201
8
810-1067
9
810-1668
10
810-3591
11
810-3738
12
813-0022
13
813-0062
14
813-0298
15
813-0331
16
813-0555
17
813-0908
18
813-0940
19
824-2223
20
816-0220
21
807-4101
* Not illustrated.
√ Recommended parts.
4
7
17
4
10
15
6
7
13
Non-Top Off Return
Valve Assy’s
6
8
7
5
4
8
9
6
7
4
See Page 2-5 for Drain
Valve Assemblies.
COMPONENT
Frypot, Full-Vat OCF with filter (use 823-8022 for frypot with no filter)
Frypot, Dual-Vat OCF with filter (use 823-8020 for frypot with no filter)
Riser, DV Frypot
Valve, Check ½” 1 PSI
Elbow, St ½” x ½” NPT 90° BM
Handle, Valve Rear Flush LT
Handle, Valve Rear Flush RT
Retainer, Nut Oil Return Valve
Valve, Return ½” Ball LT
Flexline, ⅝” OD x 8.50” Long Return Oil
Adaptor, Male ⅝” OD x ½”
Flexline, ½” OD x 8.00” Long Top Off
Adaptor, Check Valve Close NPL
Nipple, ½” Close NPT BM
Elbow, ½” BM x 90°
Nipple, ½” x 2.00” NPT BM Pipe
Elbow, V-Side Outlet ½” NPT
Reducer, Bell ½” to ¼” NPT BM
Adapter, ½” NPT 90° (also used in DV non-Top Off manifolds in place of item 4)
Elbow, ¼” NPT x ⅜” Flare
Cover, Oil Return Microswitch
Insulation, RF Switch
Switch, Micro
2-23
2.12 Oil Return System Components
ITEM
PART #
1
809-0601
2
816-0643
3
813-0907
4
811-1071
5
108-2555SP
6
810-2493
7
813-0807
8
813-0700
9
*
810-3958
*
810-3959
*
810-3960
* Not illustrated.
COMPONENT
Clip, Clevis
Grip, Oil Return Valve Handle
Cap, 15/16-inch Valve Safety
Tube, ¼-inch OD Teflon Manifold Vent
Valve, ¼-inch NPT Solenoid
Elbow, 90° ⅛-inch NPT x ¼-inch Quick Connect
Bushing, ¼-inch NPT x ⅛-inch
Nipple, ¼-inch NPT x 3.00-inch
Manifolds
Manifold, Two-Station Fryer (use 810-2543 for non-filter units)
Manifold, Three-Station Fryer (use 810-2544 for non-filter units)
Manifold, Four-Station Fryer (use 810-2545 for non-filter units)
2-24
2.13 Auto Top-Off Components
2.13.1 JIB Basket and Automatic Top-Off Box Assembly
1
3
9
8
4
5
108-2557SP 120V Assy
ITEM
PART #
1
108-2556
2
220-5679
√ 3
108-2805
√ 4
807-2181
√ 5
807-0855
√ 6
807-2180
√ 7
807-2191
8
807-1321
√ *
807-1597
√ 9
807-1683
10
220-8363
* Not illustrated.
√ Recommended parts.
2
6
7
10
108-2558SP 208-240V Assy
COMPONENT
Box, Assembly Auto Top Off Board
Cover, Top Off Board Box
PCB Board, Automatic Top Off OCF
Transformer, 100-120V/24V 62VA
Transformer, 120V 50/60-12V 20VA
Transformer, 208-240V/24V 50VA
Transformer, 208/230/240 -12V 30VA
Holder, Fuse AGC Panel Mount ¼”
Fuse, 3A Slow-Blow
Relay, 12VDC (Top off pump)
Cradle, JIB (use 826-3013 for screw kit)
NOTE: Top off boxes for vats 4 and 5 have either item 4 or item 6, both have item 3.
2.13.2 JIB Cap and Pick Up Assembly
ITEM
1
2
3
4
PART #
108-1049SP
823-7575
810-3663
810-3300
810-3664
COMPONENT
Cap, JIB Assembly (use 106-9495SP for Intl. BIB)
Cap, JIB (use 823-6812 for Intl. BIB)
Hose, JIB
Inlet, Oil Reservoir Tube
Bushing, Heyco
2-25
2.13.3 ATO Pump Assembly
Liquid Shortening
JIB hose
connects
here.
Semi/Solid Shortening
1
7
2
8
3
8
INSTALL
O-RINGS
HERE
4
See page 2-28 for
inlet plumbing
5
ITEM
PART #
1
108-0639
2
810-3265
3
811-1139
4
810-3578
5
816-0782
6
813-0940
7
823-7167
8
816-0708
√ Recommended parts.
√
6
COMPONENT
Pump, Shurflo 24VAC
Flexline, ½” OD x 24-inch (Out to top off manifold)
Hose, Silicone Braided (sold by the foot)
Fitting, Shurflow Pump OCF
O-Ring, Viton #111
Elbow, ¼” NPT x ⅜ Flare
Bracket, JIB Elbow
Fitting, ¼” NPT Male Barb
2-26
2.13.4 ATO Top-Off Manifolds and Components
Connects to item #10 on page 2-23
Connects to item #2 on the
preceding page
ITEM
1
PART #
810-3812
810-3813
810-3814
√
2
108-2555
3
810-0838
4
810-3270
5
813-0640
√ Recommended parts.
COMPONENT
Manifold, Top-Off Two Station Fryer
Manifold, Top-Off Three Station Fryer
Manifold, Top-Off Four Station Fryer
Solenoid Top-Off
Nipple, ¼” NPT BM Close
Fitting, ⅜” Flare x ¼” NPT
Plug, ¼” Square Head
2-27
2.13.5 Shortening Melting Unit
ITEM
PART #
108-3406
1
108-2983
2
108-3001
3
810-3957
4
108-3372
5
810-0180
√ 6
826-1392
7
813-0568
8
823-8079
823-8147
9
810-1669
10
810-1055
11
810-1668
12
813-0062
13
810-3820
14
816-0782
15
807-5268
16
807-4036
17
807-1321
*
807-1555
*
807-1098
*
807-1419
*
807-1473
* Not illustrated.
√ Recommended parts.
COMPONENT
Assembly, Heated Shortening
Box Assembly, Heated Shortening
Assembly, Heated Shortening Lid
Pan, Heated Shortening
Cover, Shortening Box Front
Handle
O-Ring (Pkg. of 5)
Plug, ⅛-inch Socket Head Pipe
Bracket W/A, Shortening Suction 3 battery
Bracket W/A, Shortening Suction 4 battery
Adaptor, Female ⅞” OD x ½”
Flexline, ⅝” OD x 11.5-inch
Adaptor, Male ⅝” OD x ½”
Elbow, ½” Blk 90° NPT BM
Fitting, Quick Connect Shurflo Pump
O-Ring, Viton #111
Strips, Hot Box Heater with controller
Switch
Holder, Fuse
Fuse 5 Amp
Heater Strip Assembly, 240V, 25W 18”
Heater Strip Assembly, 240V, 45W 36”
Heater Strip Assembly, 240V, 70W 56”
2-28
2.13.6 Bulk Oil Relay Box and Switch
ITEM
PART #
1
108-3409
2
108-3410
3
108-3412
4
108-3413
5
220-8665
6
220-8666
7
807-1068
√ 8
807-5303
√ 9
807-5304
√ 10
807-5310
11
220-8706
12
807-5309
√ 13
807-4678
√ 14
807-5308
*
826-2985
*
826-2986
* Not illustrated.
√ Recommended parts.
COMPONENT
Harness, Bulk Oil Power
Harness, Bulk Oil Control
Harness, Bulk Oil Switches
Harness, Bulk Oil Communication
Box, Bulk Oil Relay
Cover, Bulk Oil Relay Box
Connector, 2-pin
Relay, 24VAC 3PDT
Relay, 24VAC DPDT
Relay, 2 Second Time Delay
Bracket, OCF Bulk Oil Control
Light, Amber, 24VAC
Switch, Momentary
Switch, 3 Position
Kit, Bulk Oil 2-Battery for fryers without bulk oil installed
Kit, Bulk Oil 3-Battery for fryers without bulk oil installed
2-29
2.13.7 Bulk Oil Plumbing
To Drain
To Bulk Oil Fresh To Oil Return
Manifold To Bulk Oil Waste
Connection
Connection
To JIB
ITEM
PART #
1
106-6830
2
108-3368
3
220-8661
4
813-0838
5
810-0555
6
809-0417
7
809-0949
8
810-1055
9
810-1069
10
810-1400
11
810-1668
12
810-1680
√ 13
810-3531
14
810-3583
15
800-3738
16
813-0003
17
813-0022
18
813-0165
19
813-0304
20
813-0543
21
220-5656
22
220-5657
23
823-8118
24
810-3587
25
809-0657
26
810-1067
√ 27
810-0667
28
810-1669
* Not illustrated.
√ Recommended parts.
√
COMPONENT
Solenoid Assy
Valve, Assy Waste Dispose (see next page for valve assembly)
Brace, Front Bulk Plumbing
Nipple, ¼” NPT
Reduce, Bell ½” to ¼” NPT
Nut, Flange ¼” - 20
U- Bolt ¼” – 20 x 1 ¼
Flexline, ⅝” OD x 11.50”
Flexline, ⅝” OD x 29.50” 3, 4 and 5 battery (use 810-1055 for two battery)
Flexline, ⅝” OD x 21.00”
Adaptor, Male ⅝” OD x ½”
Flexline, ⅝” OD x 6.50”
Valve, Check 20 PSI (Bypass)
Valve, Check 4 PSI (Manifold)
Adapter, Check Valve
Tee, ½” x ½” x ½”
Nipple, ½” x Close NPT
Elbow, St ½” x ½” NPT 90° BM
Bushing, ½” x ¼: BM Flush
Elbow, Street ¼” NPT
Brace, Handle (use 220-8633 for 2-battery (Assembly 108-3387))
Cover, Handle (use 220-8664 for 2-battery)
Handle, Waste Pull
Lock and Key, Waste Handle
Clip, Clevis Right Rod End
Flexline, ⅝” OD x 8.50”
Valve, Check 1 PSI (Pump Motor)
Adapter, Female ⅞” OD x ½”
2-30
2.13.8
Bulk Oil Dispose Waste Valve
ITEM
PART #
108-3368
1
108-0445
2
220-5615
√ 3
807-2103
4
810-0278
5
900-2935
6
901-2348
7
902-2348
√ Recommended parts.
COMPONENT
Valve, Dispose Waste Assembly
Bracket, Waste Valve
Handle, Waste Valve
Microswitch
Valve, ½” Ball
Retainer, Nut Return Valve
Cover, DV Safety Switch
Cover, DV Safety Switch
2-31
2.14
Wiring Connectors, Pin Terminals and Tools
ITEM
PART #
807-1068
1
807-0158
2
807-0156
3
807-0159
5
807-0875
5
807-1067
6
807-0157
7
807-0155
8
807-0160
9
807-0804
10
826-1341
11
826-1342
12
807-2518
13
807-0928
14
806-4855
15
230-2345
16
* Not illustrated.
COMPONENT
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)
Extract Tool Pin Pusher
Pin Pusher Screwdriver Assy
SMT Pin Extractor
2-32
2.15
Fasteners
ITEM
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
PART #
809-0429
809-0131
809-0953
807-1926
809-0514
809-0448
826-1351
809-0171
826-1366
826-1358
809-0247
809-0052
826-1376
809-0766
809-0581
809-0020
826-1372
809-0417
809-0535
809-0495
809-0804
826-1362
809-0540
809-0656
826-1359
826-1365
809-0098
809-0357
809-0359
809-0360
826-1371
809-0364
809-0441
809-0362
809-0518
809-0104
826-1363
826-1360
809-0123
826-1330
809-1003
809-0938
826-1375
809-1000
826-1374
809-0266
COMPONENT
Bolt, ¼-inch – 20 x 2.00-inch Hex Head ZP Tap
Bolt, ¼-inch -20 x ¾-inch Hex
Bolt, ¼-20 x ¾-inch Hex Head
Bushing, .875-inch Split
Capscrew, 5/16-inch-18 NC Hex
Clip, Tinnerman
Nut Retainer, ¼-20 (Pkg. of 10 – for basket hanger thumbscrew) Std. Fluecap
Thumbscrew, ¼-20 x 1⅜-inch (for use on Standard Fluecap)
Nut, 4-40 Keps Hex (Pkg. of 25) (809-0237)
Nut, 6-32 Keps Hex (Pkg. of 25) (809-0049)
Nut, 8-32 Keps Hex
Nut, 10-24 Hex
Nut, 10-32 Keps Hex (Pkg. of 10) (809-0256)
Nut, 10-32 Keps Hex SS
Nut, ½ NPT Locking
Nut Cap 10-24 NP
Nut Grip ¼-inch ¼-20 Hex NP (Pkg. of 10) (809-0059)
Nut Flange ¼-inch ¼-20 Serr
Nut, "T" ¼-inch-20 x 7/16 SS
Nut, ¼-inch - 20 Press
Nut, ¼- inch - 20 Keps Hex
Nut, ¼-20 Hex (Pkg. of 10) (809-0071)
Nut, Lock ½-inch-13 Hex 2-Way ZP
Screw, 4-40 X 3/8-inch Slotted Round Head
Screw, 4-40 x ¾-inch Slotted Round Head (Pkg. of 25) (809-0354)
Screw, 6-32 x ⅜-inch Slot Head (Pkg. of 25) (809-0095)
Screw, 6-32 x 1¼-inch Slotted Round Head
Screw, 6 x ⅜-inch Phillips Head NP
Screw, 8 x ¼-inch Hex Washer Head
Screw, 8 x ⅜-inch Hex Washer Slot Head
Screw, 8 x ½-inch Hex Head ZP (Pkg. of 25) (809-0361)
Screw, 8 x ⅝-inch Hex Washer Head ZP
Screw, 8 x 1½-inch Hex Washer Head
Screw, 8 x 1¼-inch Hex Washer Head Drill Point
Screw, 8-32 x ⅜-inch Hex Washer Slotted Head SS
Screw, 8-32 x ½-inch Slotted Head ZP
Screw, 8-32 x ½-inch NP (Pkg. of 25) (809-0103)
Screw, 10-24 x 5/16-inch Round Slot Head ZP (Pkg. of 25) (809-0024)
Screw, 10-24 x 3/4-inch Slotted Truss Head
Screw, 10-32 x ⅜-inch Slot Head SS (Pkg. of 25) (809-0117)
Screw, 10-32 x ⅜-inch Hex Trim Head SS
Screw, 10-32 x ⅝-inch Philips Truss Head
Screw, 10-32 x ¾-inch Hex Trim Head SS (Pkg. of 5) (809-0401)
Screw, 10-32 x 1¼-inch Hex Sck C/S
Screw, 10 x ½-inch Hex Head (Pkg. of 25) (809-0412)
Screw, 10 x ½-inch Phillips Head ZP
continued on the following page
2-33
2.15
ITEM
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Fasteners cont.
PART #
809-0500
809-0434
809-0123
826-1389
826-1346
810-2763
826-1340
810-0500
810-2023
200-6721
826-1337
807-0070
807-1948
807-1359
826-1383
809-0582
809-0184
809-0190
809-0191
809-0193
809-0194
809-0196
810-1165
COMPONENT
Screw, 10 x ½-inch Hex Washer Head 410 SS
Screw, 10 x ⅜-inch Hex Washer Head NP
Screw, 10 x ¾-inch Slot Head
Screw, ¼-20 x ¾-inch Hex Head ZP (Pkg. of 10) (809-0131)
Spacer, Ignition Module (Pkg. of 10)
Spacer, Interface Board
Spacer, .25-inch x 1.187-inch (Pkg. of 10)
Spacer, .25-inch x .9375-inch
Spacer, .25-inch x .110-inch (Used on drain valves.)
Plate, Strain Relief
Tab, ¼-inch Terminal (Pkg. of 5)
Terminal, Ground Lug
Ty-Wrap
Mount, Ty-Wrap
Washer, ¾-inch O.D. x ¼-inch I.D. ZP (Pkg. of 5) (809-0435)
Washer ½ NPT Locking
Washer, #10 LK ZP
Washer, .625 X .275 X 40 Flat SS
Washer, Lock ¼ Spring ZP
Washer, Flat ¼ Nylon
Washer, Flat 5/16 ZP
Washer, ⅜-inch Flat
Washer, ⅜-inch Teflon
2-34
Frymaster, L.L.C., 8700 Line Avenue, Shreveport, Louisiana 71106
TEL 1-318-865-1711
FAX (Parts) 1-318-219-7140
PRINTED IN THE UNITED STATES
FAX (Tech Support) 1-318-219-7135
SERVICE HOTLINE
1-800-551-8633
819-6688
JAN 2013
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