Instruction/ maintenance manual of the product 8196203 Frymaster
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Frymaster, a member of the Co mmercial Food Eq uipment Service Asso ciation, recomm ends using CFESA Certified Tec hnicians. 24-Hour Service Hotline 1-800-551-8633 NOV 08 www.frymaster.com E-mail: service@frymaster.com *8196203* This manual i s applicable t o fryers m anufactured beginning May 2006 with serial numbers beginning with 0604.
NOTICE IF, DURING THE WARRANTY PERIOD, THE CUST OMER USES A PART FOR THIS ENODI S EQUIPMENT OTHER TH AN AN UNMODIFIED NEW OR RECYCLED PART PU RCHASED DIRECTLY FROM FRYMASTER DEAN, OR ANY OF IT S AUTHORIZED SERVICE CE NTERS, AND/OR THE PART BEIN G USED IS MODIFIED FR OM ITS ORIGINAL CONFIGURATI ON, THIS WARRANTY WILL BE VOID.
NOTICE This appliance is intended for professional use only and is to be operated by qualified personnel only. A Frymaster DEAN Factory Authoriz ed Service Center (FASC) or other qualified professional should perform installation, maintenance, and repairs.
i Navy Surface Ship Electric Fryers Installation, Operation, Service, an d Parts Manual TABLE OF CONTENTS Page Chapter 1: Introduction 1-1 Chapter 2: Installation Instructions 2-1 Chapter 3: Operating.
1-1 NAVY SURFACE SHIP ELECTRIC FRYERS CHAPTER 1: INTRODUCTION 1.1 General Read the instructions in this manual thoroughly before attempting to operate this equipm ent. This manual covers all configurations of Navy Surface Ship Electric Fryer models specifically configured for use aboard surface ships of the U.
1-2 1.3 Controller Information This equipment has been tested and found to comply with the lim its for a Class A digital device, pursuant to Part 15 of the FCC rules. While this device is a verified Cl ass A device, it has been shown to meet the Class B limits.
2-1 NAVY SURFACE SHIP ELECTRIC FRYERS CHAPTER 2: INSTALLATION INSTRUCTIONS 2.1 Introduction The instructions in this chapter cov er all configurations of Navy Su rface Ship Electric Fryer models specifically configured for use aboard surface ships of the U.
2-2 DANGER All wiring connections for this appliance must be made in accor dance with the wiring diagram(s) furnished with the app liance. Refer to the wiring diagram(s) affixed to the inside of the applian ce door when installing or servicing this equipment.
2-3 2.2 Power Requirements AMPS PER LEG MODEL VOLTAGE PHASE WIRE SERVICE MIN. SIZE AWG (mm 2 ) L1 L2 L3 H14SC 440 3 3 8 (10) 19 19 19 H14SC 480 3 3 8 (10) 17 17 17 H17SC/FPH17SC 440 3 3 6 (16) 23 23 2.
2-4 2.4 After Fryers Are Anchor ed At the Frying Station DANGER Hot oil can cause severe burns. Avoid contact. Under all circumstan ces, oil must be removed from the fryer before attempting to move it to avoid oil spills, falls a nd severe burns. This fryer may tip and cause personal injury if not secured in a stationary position.
2-5 Back o f Fr yer Unit 33.38 28.29 17.534 20.48 10.580 2.465 15.67 20.48 Front Handle Mounting Holes Ø .625, 4 Places Single Fryer (non-filter) 31.62 7.098 Typica l 2.470 26.316 17.515 33.39 31.45 31.62 Back of Fryer Uni t Front Handle Mounti ng Holes Ø .
2-6 7.229 17.516 27.570 14. 400 33.24 32.66 32.66 47.1 22.66 22.6 6 Front Handle Back o f Fryer Uni t Mounting Holes Ø .625, 4 Places 3-Fryer Battery 2.470 7.119 17.490 62.55 31.180 7.119 33.45 31.61 31.61 Front Handle 26.320 35.76 35.76 Back of Fryer Unit Moun tin g Hol es Ø .
3–1 NAVY SURFACE SHIP ELECTRIC FRYERS CHAPTER 3: OPERATING INSTRUCTIONS 3.1 Equipment Setup and Shutdown Procedures Setup DANGER Never operate the appliance with an empty frypot. The frypot must be filled with water or cooking oil before energizing the el ements.
3–2 Shutdown 1. Turn the fryer off. 2. Filter the cooking oil and clean the fryers (See Chapters 4 and 5). 3. Place the frypot covers on the frypots. 3.2 Operation of the Soli d-State Analog Controller NOTE: Refer to Chapter 4 of this manual for operati ng instructions for the bui lt-in filtration system.
3–3 The analog controller has no timing features. The operator must m onitor shake and pull times. WARNING Before pressing the power sw itch to the ON position, ensure that the frypot is properly filled with oil. See Section 3.1. CONTROLLER OPERATING PROCEDURE 1.
3–4 4. Press and hold the high -limit test switch in the “2 nd ” test position until the 2 nd High-Lim it light illuminates. Release the switch. The 2 nd High-Limit light should have come on wh en the temperature was between 430°F and 460°F.
4-1 NAVY SURFACE SHIP ELECTRIC FRYERS CHAPTER 4: FILTRATION INSTRUCTIONS 4.1 Introduction The FootPrint Pro filtration system allows the cooking oil or shortening in one frypot to be safely and efficiently filtered while the other frypots in a battery rem ain in operation.
4-2 3. Place the metal filter screen in the center of the bottom of the pan, then lay a sheet of filter paper on top of the screen, over- lapping on all sides. 4. Position the hold-down ring over the filter paper and lower the ring into the pan, allowing the paper to fold up around the ring as it is lowered to the botto m of the pan.
4-3 DANGER Do not drain more than one frypot at a ti me into the built-in fi ltration unit to avoid overflow and spillage of hot oil. DANGER NEVER attempt to clear a clogged drain valve fr om the front of the valve! Hot oil will rush out creating the potential for severe burns.
4-4 DANGER The crumb tray must be emptied into a fireproof container at the end of frying operations each day. Some food particles can spontaneousl y combust if left soaking in certain shortening. WARNING Do not bang fry baskets or other utensils on the fryer’s joiner strip.
5–1 NAVY SURFACE SHIP ELECTRIC FRYERS CHAPTER 5: PREVENTIVE MAINTENANCE 5.1 Cleaning the Fryer 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 so aking in certain shortening materia l.
5–2 5.1.3 Clean the Frypot and Heating Elements – Weekly DANGER Never operate the appliance with an empty frypot. The frypot must be filled with water or cooking oil before energizing the el ements. Failure to do so will result in irreparable damage to the elements and may cause a fire.
5-3 5.1.4 Clean Detachable Parts and Accessories – Weekly Wipe all detachable parts and accessories with a clean, dry cloth. Use a cl ean cloth saturated with detergent to remove accumulated carbonized oil on det achable parts and accessories. Rinse the parts and accessories thoroughly with clean wa ter and wipe dry before reinstalling.
5–4 5.3 Annual/Periodic System Inspection This appliance should be inspected and adjusted periodically by qualified service personnel as part of the galley material main tenance management (3M) program.
5-5 • Verify that all O-rings and seals (including those on the quick-disco nnect fittings) are present and in good condition. Replace O-rings and seals if worn or damaged. • Check filtration system integrity as follows: • Verify that filter pan cover is present and properly installed.
6-1 NAVY SURFACE SHIP ELECTRIC FRYERS CHAPTER 6: OPERATOR TROUBLE SHOOTING 6.1 Introduction This section provides an easy reference guide to some of the common problems that m ay oc cur during the operation of this equipment.
6-2 6.2 Troubleshooting 6.2.1 Control and Heating Problems Problem Probable Causes Corrective Action A. Power cord is not plugged in or circuit breaker is tr ipped. A. Plug power cord in and verify that circuit breaker is no t tripped. B. Controller has failed.
6-3 Problem Probable Causes Corrective Action Fryer repeatedly cycles on and off when first started. Fryer is in melt-cycle mode. This is normal. The standard operational mode for the controller is for the elements to cycle on and off until the temperature in the frypot reaches 180ºF (82ºC).
6-4 6.2.2 Error Messages and Display Problems Problem Probable Causes Corrective Action Controller trouble light ON. Oil temperature above acceptable range or a problem with the temperature measuring circu itry.
6-5 Problem Probable Causes Corrective Action Filter pump runs but oil does not return to frypot and there is no bubbling oil. Blockage in filter pan suction tube. Test: Close the drain valve and pull the filter pan out from the fryer. Activate the pump.
7-1 NAVY SURFACE SHIP ELECTRIC FRYERS CHAPTER 7: SERVICE PROCEDURES 7.1 General Before performing any maintenance on this equipm ent, disconnect the fryer from the electrical power supply. When electrical wires are disconnected, it is recommende d that they be marked in such a way as to facilitate re-assemb ly.
7-2 4. Dismount the component to be replaced and inst all the new component, being sure that any required spacers, insulation, washers, etc. are in place. NOTE: If more room to work is required, the c ontrol panel frame assembly may be rem oved by removing the hex head screws that secure it to th e fryer cabinet (s ee illustration below).
7-3 3. Remove the four screws from both the left and right sides of the lower back panel. 4. Locate the high-limit that is being replaced and follow the two-black wires to the 12-pin connector C-6. Note where the leads are connected prior to removing them from the connector.
7-4 6. Gently pull on the temperature probe and grommet. Pulling the wires up the rear of the fryer and through the element tube assembly. 7. Insert the replacement temperature probe (wires first) into the tube assembly ensuring that the grommet is in place.
7-5 2. On dual-vat fryers, and on full-vat fryers where th e temperature probe is a ttached to the elem ent being replaced, disconnect the wire harness co ntaining the probe wiring. Using a pin pusher, disconnect the probe wires fr om the 12-pin connector C-6.
7-6 8. Reconnect the element connector it was removed fr om directly behind th e frypot, ensuring that the latches lock. 9. Insert the temperature probe lead s into the 12-pin wiring harness connector C-6 (see illustration below).
7-7 4. The contactors and relays are held on by threaded pin studs so that only removal of the nut is required to replace the component. 5. After performing necessary service, reverse st eps 1-4 to return the fryer to operation. Left and right views of mechanical contactor box com ponents.
7-8 12. Re move the top-connecting strip that cove rs the joint with the adjacen t frypot. 13. Unscrew the Teflon vent/vacuum-breaker tube f itting, unscrew the nut located on the front of each section of drain tube, and remove the tub e assembly from the fryer.
7-9 27. Reinstall the top connecting strips, to p cap, tilt housing and back panels. 28. Reinstall controllers in the control panel fram e and reconnect the wiring harnesses and ground wires. 29. Reposition the fryer under the exhaust hood and r econnect it to the el ectrical power supply.
7-10 particles and sediment to pass through the filter pan and into the pump. When sediment enters the pump, the gears bind, causing the motor to ove rload, again tripping the therm al overload. Shortening that has solidified in th e pump will al so cause it to seize, with the same result.
7-11 4. Loosen the nut and bolt that secures the bri dge to the oil-return manifold. 5. Remove the cover plate from the front of the motor and disconnect the motor wires.
7-12 7.9.3 Replacing the Filter Tran sformer or Filter Relay Remove the left controller from the fryer to expose the in terior of the left component box.
7-13 7.10 Interface Board Diagnostic Chart The following diagram and charts provide ten quick system checks that can be perform ed using only a multim eter.
7-14 7.11 Probe Resistance Chart Probe Resistance Chart For use with fryers manufactured with Minco Thermistor probes only. F OHMS C F OHMS C F OHMS C F OHMS C F OHMS C 60 1059 16 130 1204 54 200 1350.
7-15 7.12 Wiring Diagram, System H14SC/H17SC/H22SC kW Single Fr yers a nd FPH17SC kW Filter System Fryers 440-480V, 60 Hz, 3-Ø, 3-Wire Configurations Refer to page 2-2 for power requirements.
7-16 7.13 Wiring Diagram, Contactor Box H14SC/H17SC/H22SC kW Single Fr yers a nd FPH17SC kW Filter System Fryers 440-480V, 60 Hz, 3-Ø, 3-Wire Configurations Refer to page 2-2 for power requirements.
7-17 7.13 Wiring Diagram, Contactor Box cont. H14SC/H17SC/H22SC kW Single Fr yers a nd FPH17SC kW Filter System Fryers 440-480V, 60 Hz, 3-Ø, 3-Wire Configurations Refer to page 2-2 for power requirements.
7-18 7.14 Wiring Diagram, Wiring Harness.
7-19 7.15 Components Descrip tion of Operation A. Drain solenoid - When the return valve is opene d, a microswitch activates and supplies 24V to the pump relay and solenoids. B. Vacuum release solenoid - When the return valve is closed, it de-energizes the 24V to the pump relay and solenoid s releasing the vacuum.
8-1 NAVY SURFACE SHIP ELECTRIC FRYERS CHAPTER 8: PARTS LIST 8.1 Accessories 1 2 3 4 5 6 7 8 9 ITEM PART # COMPONENT 1 809-0171 Thumbscrew, ¼ -20 X 1 3 / 8 -inch 2 810-2793 Hanger, Wireform Basket 3 8.
8-2 8.2 Cabinetry 8.2.1 Backs, Control Panels, Doors, Handl es, Sides, Tilt Housings & Top Caps 4 6 1 2 3 5 9 10 11 8 7 12 14 13.
8-3 8.2.1 Backs, Control Panels, Doors, Handl es, Sides, Tilt Housings & Top Caps (cont.) ITEM PART # COMPONENT 1 230-0675 Back Panel, Upper - Si ngle 230-0676 Two Station Fr yer 230-0677 Three St.
8-4 8.2.2 Cabinets, Bases, Braces, and Associated Parts See Page 8-22 through 8-24 for filter rails and associated hardw are . See Page 8-26 for rear bridge support/ oil return manifold.
8-5 8.2.2 Cabinet Bases, Braces, a nd Associated Parts (cont.) ITEM PART # COMPONENT 1 106-3828 Upright Assembly, Left 2 106-3829 Upright Assembly, Right 3 200-1651 Support, Cross Cabinet 4 200-1659 D.
8-6 8.3 Drain System Components 8.3.1 Drain Tube Sections and Associated Parts 8 7 7 6 6 1 3 3 4 4 5 2 2 1 See next section for Drain Valve Detail.
8-7 8.3.1 Drain Tube Section and Associated Parts (cont.) ITEM PART# COMPONENT 1 Drain Tube, Left/Right End Short 823-4625 Full-Vat 3” 823-4624 Dual-Vat 3” 2 Drain Tube, Left/Right Open Short 823-.
8-8 8.3.2 Drain Valve Assembly and Assoc. Pa rts (Units with Bu ilt-In Filtration) ITEM PART # COMPONENT 1 809-0540 Nut, ½-13 2-Way Hex Lock 2 900-2936 Retainer, Full-Vat Nut Drain Valve 3 824-1602 H.
8-9 8.3.2 Drain Valve Assembly and Assoc. Parts cont. (Units with Built-In Filtration) ITEM P A R T # COMPONENT 1 809-0540 Nut, ½-13 2-Way Hex Lock 2 900-2936 Retainer, Full-Vat Drain Valve Nut 3 824.
8-10 8.3.2 Drain Valve Assembly and Assoc. Parts cont. (Units with Built-In Filtration).
8-11 8.3.2 Drain Valve Assembly and Assoc. Parts cont. (Units with Built-In Filtration) ITEM P A R T # COMPONENT 1 816-0639 Cap, Drain Handle 2 809-0539 Nut, ⅜ -16 2-Way Hex Lock 3 900-2934 Retainer.
8-12 8.4 Electronics and Wiring Components 8.4.1 Component Boxes ITEM PART # COMPONENT 1 106-5846 Box Assembly, Component 2 210-9002 Bracket, Component Box Strain Relief 3 230-1057 Bracket, Circuit Breaker 4 806-9495SP Terminal Block and Wire Assembly 5 807-0012 Relay, Filter 18 Amp ⅓ HP 24V Coil 6 826-1337 Terminal, ¼-inch Push-on (Pkg.
8-13 8.4.1 Component Boxes cont. ITEM PART# COMPONENT 18 210-8995 Brace, Component Box 19 807-1083 Bushing, Heyco 20 807-3868 Strain Relief 21 807-0121 Bushing, Heyco SB-625-500 22 816-0217 Paper, Ins.
8-14 8.4.2 Contactor Boxes NOTE 1: Left and right contactor box assemblies are mirror images of one another. W ith the exception of the box itself, all components of a left -hand assembly, are the sam e as those in the corresponding right-hand asse mbly and vice versa.
8-15 8.4.2 Contactor Boxes cont. ITEM PART # COMPONENT 106-6278 Assembly, Contactor Box Left 106-6279 Assembly, Contactor Box Right 106-6292 Assembly, Contactor Box Single 106-6268 Assembly, Contactor.
8-16 8.4.3 Heating Element Assem bly and Associated Parts 1 1 2 3 4 5 8 11 16 12 9 17 13 18 19 10 12 17 14 15 7 28 29 6 26 21 20 23 22 24 25 21 NOTES: The only dif ferenc e be tween eleme nt assembl ies for diff erent vo lt age and kW rat ings is th e element i tself (Item 1).
8-17 8.4.3 Heating Element Assembly and Associated Parts (cont.) ITEM PART # COMPONENT 1 Element Kits – includes gaskets, grommets, tie wraps, screws and nuts. 826-2195 440V 1 7.0 kW 826-2202 440V 1 8.5 kW 826-2211 440V 11.0 kW 826-2196 480V 1 7.0 kW 826-2203 480V 1 8.
8-18 8.4.4 Controller Controller P /N 806-3798 Knob P/N 810-038 7 Power Swit ch P/N 807-08 12 High-Limit Switch P/N 80 7 -0811 8.4.5 Wiring 8.4.5.1 Contactor Box Wiring Assembly – 12-Pin Full-Vat C-1 8.
8-19 8.4.5.3 Contactor Box Wiring A ssemblies – 9-Pin (Right Element) 8.4.5.4 Main Wiring Harness 8.4.5.5 Component Box and F ilter Pump Wiring Harnesses ITEM PART # COMPONENT 1 106-5750 Full Vat Co.
8-20 8.4.5.6 Interface Board to C ontroller Wiring Harness – 15-Pin PN 806-2071SP Standard Controller to Interface Board.
8-21 8.5 Filtration System Components 8.5.1 FPH17 Filtration Components.
8-22 8.5.1 FPH17 Filtration Components (cont.) ITEM PART # COMPONENT 106-5983 Assembly, Filter Pan Single includes pan and lid 1 106-6243 Lid, Single 2 824-1707 Crumb Tray 3 823-5774 Hold Down Ring - .
8-23 8.5.2 Multiple Battery F iltration System Components 5 6 13 14 15 7 12 11 9 12 11 10 16 30 29 25 27 26 24 23 18 24 18 35 19 33 17 20 22 25 34 28 8 32 31 1 2 3 4 8 21.
8-24 8.5.2 Multiple Battery Filtration Sy stem Components (cont.) ITEM PART # COMPONENT * 826-1979 Filter Pan Roller Kit ( four each of Items 7 and 8 ) * 826-1980 Service Filter Pan (Item 5 minus Item 2) * 826-1981 Service Filter Pan Assembly (S ervice Filter Pan above plus Items 3 & 4) * 826-1392 O-Ring (Pkg.
8-25 8.6 Frypot Assembly and Thermostat Frypot P/N 823-5359SP Thermostat P/N 806-7543.
8-26 8.7 Oil Return System Components.
8-27 8.7 Oil Return System Components (cont.) ITEM PART # COMPONENT 1 106-5848 Handle Assembly 2 813-0907 Cap, 15/16-inch Valve Safety 3 807-2103 Microswitch, Straight Lever 4 106-5847 Bracket Assembly, Microswitch 5 210-8998 Bracket, Handle Retainer 6 816-0220 Insulation, Oil Return Microswitch 7 826-1366 Nut, 4-40 Keps Hex (Pkg .
8-28 8.8 Wiring Connectors, Pin Terminals and Power Cords 1 2 4 5 3 6 7 9 10 8 11 13 12 ITEM PART # COMPONENT Power Cords * 807-3834 Cable, 3-Phase 4-Wire (Fryer Power Cable) * 807-3825 Cord, Filter S.
8-29 8.9 Fasteners ITEM PART # COMPONENT * 809-0429 Bolt, ¼-inch – 20 x 2.00-inch Hex Head ZP Tap * 809-0514 Capscrew, 5/16-inch-18 NC Hex * 809-0448 Clip, Tinnerman * 826-1366 Nut, 4-40 Keps Hex (Pkg. of 25) (809-0237) * 826-1358 Nut, 6-32 Keps Hex (Pkg.
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Frymaster, L.L.C., 8700 Line Av enue, Shrev eport, LA 71106 TEL 1-318-865-1711 FAX (Parts) 1-31 8-688 -2200 (Tech Support) 1-318-219-7135 819-6203 PRINTED IN THE UNITED STATES SERVICE HOTLINE 1-800-55.
An important point after buying a device Frymaster 8196203 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Frymaster 8196203 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Frymaster 8196203 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Frymaster 8196203 you will learn all the available features of the product, as well as information on its operation. The information that you get Frymaster 8196203 will certainly help you make a decision on the purchase.
If you already are a holder of Frymaster 8196203, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Frymaster 8196203.
However, one of the most important roles played by the user manual is to help in solving problems with Frymaster 8196203. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Frymaster 8196203 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
