Instruction/ maintenance manual of the product 8196345 Frymaster
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Frymaster, a member of the Co mmercial Food Equipm ent Serv ice Association, recommends using CFESA Certified Tec hnicians. 24-Hour Service Hotline 1-800-551-8633 FEBRUARY 2009 www.
ii NOTICE IF, DURING THE WARRANTY PE RIOD, THE CUSTOMER USES A PART FOR THIS MA NITOWOC FOOD SERVICE EQUIPMENT OTHE R THAN AN UNMODIFIED NEW OR REC YCLED PART PURCHASED DIRECT LY FROM FRYMASTER DE AN, OR ANY OF ITS AUTHORIZED SERVIC E CENTERS, AND/OR THE PART BEING U SED IS MODIFIED FROM ITS ORI GINAL CONFIGURATION, THIS WARR ANTY WILL BE VOID.
iii 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.
iv PROTECTOR ® SERIES GAS FRYERS TABLE OF CONTENTS CAUTIONARY STATEMENTS ........................................................................................................ i CHAPTER 1: Service Procedures 1.1 Functional Description .............
v PROTECTOR ® SERIES GAS FRYERS TABLE OF CONTENTS cont. 1.15 Loading and Updating Software Procedures ................................................................... 1-38 1.16 Principal Wiring Connections .........................................
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1-1 Inside the Ignition Module TD Out to Gas Valve To A l a r m 25 V + GND HV Ignition Wire Flame Sensor Coil PROTECTOR ® SERIES GAS FRYER CHAPTER 1: SERVICE PROCEDURES 1.
1-2 ignition by measuring the flow of microam ps through the flame. If the burne r 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.
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1-4 FREQUENTLY USED TEST POI NTS FOR INTERFA CE BOA RD 106-670 6 Meter Setting 12VAC Power to Controller 50VAC Scale 1 and 3 on J3 or J2 12-18 24VAC Power to Right Module 50VAC Scale 8 on J3 and GROU .
1-5 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 (.
1-6 Pressure (m bar ) Gas Si ngle Vat Natur al Gas Lacq (G20) under 20 mbar 7 Natur al Gas Groni que * (G25) under 25 mbar 10 Natur al Gas Gronique (G25) under 20 mbar 10 Butane/ Propane (G30) at 28/ .
1-7 1.8 Measuring Flame Current When the burner flame is properly adju sted, it will produce a current between 2.5 μ A and 3.5 μ A. Flame current is measured by placing a microamp (not m illiamp) meter in series with the sensing wire on the ignitor.
1-8 1.9.2 Replacing the Temperature Probe or High-Limit Thermostat 1. Disconnect the fryer from the electrical supply. 2. Drain cooking oil below the level of the probe or thermostat. 3. Lift up on the bezel to disengage the tabs on its lower edge from the control panel frame.
1-9 1.9.4 Replacing an Ignition Module 1. Disconnect the fryer from the electrical supply. 2. Lift up on the bezel to disengage the tabs on its lower edge from the control panel frame. 3. Remove the top two screws in the upper corners of the computer.
1-10 1.9.6 Replacing or Cleaning a Combustion Air Blower 1. Disconnect the blower wiring harness, remove th e blower assem bly mounting nuts, and remove the blower assembly from the fryer. If cleani ng the m otor, continue with Step 2; otherwise, install the replacement blower, reconnect the wiring harness, and then go to Step 6.
1-11 Blower Housing Blower W heel W rap th e motor a nd w ires with plastic wrap or a plastic bag. 4. Remove the plastic wrap from the blower m o tor assembly. Reassem ble 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.
1-12 Loosen this nut and rotate shutter t o open or close air intak e. 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.
1-13 5. Remove all fittings from the old gas valve and install them on the replacement valve, using Loctite ® PST56765 or equivalent pipe thread sealant.
1-14 18. If the leak persists, use a rubber hammer and a sma ll block of wood to tap the corners of the lower combustion chamber insulation retainers. Repeat steps 15 through 17. Repeat this step until no leakage is detected. 1.9.10 Replacing the Filter Motor, Filter Pump, or Filter Pump Solenoid Valve 1.
1-15 5. Grasp the upper edge of each computer and swi ng the computer downward. Unplug the computer wiring harness and grounding wire from the back of each computer. 6. Remove the computers by lifting them from the hinge slots in the control panel frame.
1-16 1.9.12 Replacing Frypot Insulation and/or Upper Burner Rails NOTE: Replacing the burner rails requires complete ly tearing down the frypot and installing new frypot insulation. Refer to the frypot exploded view below for component identification.
1-17 11. Remove the upper burner rails (11). NOTE: For the following steps, re fer to the frypot exploded view on page 1-16 for component identification.
1-18 together with two ¼” self-tapping 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.
1-19 1.10 Troubleshooting and Problem Isolation Because it is not feasible to attempt to include in this m anual every conceivable problem or trouble condition that might be encountered, this section .
1-20 Occasionally, an ignition failure situation occurs in which all components appear to be serviceable and the microamp reading is within specification, but the unit nevertheless goes into ignition failure during operation. The probable cause in this case is an intermittent failure of an ignition module.
1-21 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 frye r, that problem must also be corrected. Check for proper operation by disconnecting the wire from the i gnitor (spark plug), inserting the tip of a screw driver into the terminal.
1-22 Improper temperature control problem s can be cate gorized into melt cycle problems and failure to control at setpoint problems. MELT CYCLE PROBLEMS Initiation of the melt cycle with CM7 com puters is automatic. Problems m ay originate from the computer itself, the temperature probe, or a m alfunctioning heat relay on the interface board.
1-23 Sediment Particle FLOW Up for reverse Down for forward PUMP • 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 pum p does not rotate, there is a blockage in the pump.
1-24 100/120V Modular Basket Lift Assembly P/N 106180 7SP (TYPICAL) 1.10.6 Leakage Leakage of the frypot will usually be due to improperly sealed high-lim it thermostats, RTD’s, temperature probes, and drain fittings.
1-25 100-120V C onfi g urati on 208-250V C onfi g urati on BINDS AND JAMS Noisy, jerky or erratic movement of the lifts is us ually 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.
1-26 The wiring diagram on the Page s 1-45 and 46 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 equipmen t m alfunctions by following a logical, systematic process.
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1-28 1.11.2 Troubleshooting the Gas Valve Prior to checking for problems associated with the ga s valve, ensure that the unit is calling for heat. Also, for non-CE units, verify that the gas valve is in the ON position.
1-29 relay marking the wires to ease reassembly. Once replaced, reconnect the power. W hen replacing a filter relay in the transformer, ensure the 24VAC relay (8070012) is used. 1.12 Probe Resistance Chart Probe Resistance Chart For use with Protector ® Series fryers manufactured with Minco Thermistor probes only.
1-30 1.13.1 ATO (Automatic Top-Off) Troubleshooting Problem Probable Causes Corrective Action The yellow JIB low light won’t illuminate. A. Power not present in the transformer box. B. Failed transformer. C. Loose wire connection A. Ensure power is present in the transformer box.
1-31 1.13.2 ATO (Automatic Top-Off) Board Pin Positions and Harnesses Connector From/To Harness # Pin # Function Voltage Wire Color 1 Output DV - Vat #1 Green 2 Output FV - Vat #1 Red 3 Output DV - Va.
1-32 1.13.3 Replacing the ATO Board or Transformer Disconnect the fryer from the electrical power supply. Locate the ATO box (see Figure 1 on page 1-29), behind the JIB (Jug In Box). Remove the cover to expose the transformer and ATO board (see Figure 2).
1-33 Problem Probable Causes Corrective Action E. Power supply component or interface board has failed. E. If any component in the power supply system (including the transformer and interface board) fail, power will not be supplied to the computer and it will not function.
1-34 Problem Probable Causes Corrective Action CM7 display shows PROBE FAILURE. Problem with the temperature measuring circuitry including the probe. This indicates a problem within the temperature measuring circuitry. Check resistance of probe, if faulty replace probe.
1-35 Problem Probable Causes Corrective Action CM7 display shows software for only CM7. Loose or damaged harness Check that all harnesses between CM7’s and ATO are secure. Check for loose pins. If the problem persists, swap out computer from one bank to another and reinitialize.
1-36 1.14.3 CM7 Menu Summary Tree Reflected below are th e major programming sections in the CM7 an d the order in wh ich submenu heading s will be found under the sections in the Install ation and Operation Manual . Adding New Menu Items See section 4.
1-37 1.14.4 CM7 Board Pin Positions and Harnesses Connector From/To Harness PN Pin # Function Voltage Wire Color 1 12VAC In 12VAC 2 Ground 3 12VAC In 12VAC 4 FV Heat Demand 5 V Relay 12VDC 6 DV Heat D.
1-38 1.15 Loading and Updating Software Procedures Loading Software from an SD card to an CM7 Computer and ATO Board To update CM7 and ATO software follow these steps: 1. Switch all computers to OFF . Press the TEMP button to check current CM7/ATO software version.
1-39 1.16 Principal Wiring Connections.
1-40 1.17 Wiring Diagrams 1.17.1 Main The Heat Strip is not present here on 330’s. Refer to "PRINCIPAL WIRING CONNECTIONS" on Page 1-39 for detail of connection points J1, J2, J3.
1-41 1.17.2 Transformer / Filter Boxes 1.17.2.1 FPGL230 and 430 Transformer / Filter Box (Domestic).
1-42 1.17.2.2 FPGL330 Transformer / Filter Box (Domestic).
1-43 1.17.3 Modular Basket Lift (100/120V).
1-44 1.17.4 Modular Basket Lift (208/250V).
1-45 1.18 Simplified Wiring Diagrams 1.18.1 FPGL30 Series Full Vat K 3 H E A T R E L A Y A I R O P T I O N A L A I R S W I T C H B L O W E R H I G H L I M I T 1 2 V 2 4 V T E M P P R O B E 2 4 V L E D.
1-46 1.18.2 FPGL30 Series Full Vat (Australia and Pacific Rim ) K3 HEAT RELAY OPTIONAL AIR SWITCH BLOWER 12V 24V TEMP PROBE 24V LED 3 LED 5 R-GV R- HEAT LED 4 R PWR V1S ALARM LED 6 12V L HEAT LED 2 L .
1-47 1.18.3 FPGL30 Series Simplified Wiring.
1-48 1.18.4 FPGL30 Series Data Network Flow chart.
2-1 PROTECTOR ® SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2.1 Accessories ITEM PART # COMPONENT 1 803-0209 Brush, Frypot 2 803-0197 Cleanout Rod, 27-inch 3 810-2793 Hanger, Basket 4 809-0171 Thumbscrew.
2-2 2.2 Basket Lift Assembly and Associated Parts.
2-3 2.2 Basket Lift Assembly and Associated Parts cont. ITEM PART # COMPONENT 1 200-2942 Mount, Modular Basket Lift 2 806-5964SP Motor Assem bly, Modular Basket Lift 3 807-2133 Capacitor, 12.
2-4 2.3 Doors, Sides, Flue Caps, Top Caps and Casters 5 4 6 1 2 3 7 8 9 10 ITEM PART # COMPONENT 1 211-6510 Side, Standard Cabinet Left SS (use 221-0323 for Enameled Steel) 2 212-6510 Side, Standard C.
2-5 2.4 Drain System Components 2.4.1 Drain Valves and Associated Parts ITEM PART # COMPONENT 1 809-0540 Nut, ½-13 2-Way Hex Lock 2 900-2936 Retainer, Nut Drain Valve 3 810-3350 Handle, Drain Valve F.
2-6 2.4.2 Drain Tube Sections and Associated Parts ITEM PART # COMPONENT 1 823-6610 4625 Drain Tube, Full-Vat Left Closed/Right End Open 2 823-6467 Drain Tube, Dump GL30 3 823-6615 Drain Tube, Dump GL.
2-7 2.5 Electronics and El ectrical Components 2.5.1 Component Boxes.
2-8 2.5.1 Component Boxes cont. ITEM PART # COMPONENT 1 810-1164 Block, One-Piece Screwless Term inal 2 816-0217 Insulation, Term inal Block Paper 3 807-3843 Fuse 3A 250V Domestic 807-3293 Fuse 5A 125.
2-9 2.5.2 Transformer Boxes.
2-10 2.5.2 Transformer Boxes cont. ITEM PART # COMPONENT Box Assembly, Transform er A 106-9021SP FPGL230 B 106-9022 FPGL330 C 106-9734 GL230 CE Export D 106-9710 GL330 CE Export E 106-5801 GL430/252 1.
2-11 2.5.3 Computers and Associated Components NOTE: See Page 2-7 for Interface Board to Computer Wiring Harness. ITEM PART # COMPONENT Replacement CM7 Computer 108-0231 Non-CE CM7 (For use in US, Canada, Mexico and all other non-CE coun- tries) * 810-3141 Sound Device, Universal SMT * Not illustrated.
2-12 2.6 Wiring 2.6.1 Main Wiring Harnesses 2-PIN FEMALE CONNECTOR 12-PIN MALE CONNECTOR 12-PIN MALE CONNECTOR 9-PIN M ALE CONNECTOR 6-PIN MALE CONNECTOR 12-PIN MALE CONNECTOR 12-PIN MALE CONNECTOR 2-PIN FEMALE CONNECTOR 807-1978 807-4014 ITEM PART # COMPONENT 807-1978 U.
2-13 2.6.2 CM7 and ATO Wiring Harnesses (Refer to wiring diagram on page 1-49.) ITEM PART # COMPONENT * 807-4546 Computer Communication (used from Computer to Computer) * 807-4655 FV Harness RTD Mediu.
2-14 2.7 Frypots and Associated Components 2.7.1 Full-Vat Frypot Components NOTE: All insulation and gaskets can be ordered in a single kit, P/N 826-2595.
2-15 2.7.1 Full-Vat Frypot Components cont. ITEM PART # COMPONENT 106-8978SP Frypot Assembly Full-Vat Protector ® HE (NAT) 106-8979 Fry pot Assembly Full-Vat Protector ® HE (PRO) 826-2595 Insulation.
2-16 2.7.2 Frypot Assemblies and Associated Parts 1 2 3 4 5 ITEM PART # COMPONENT 1 106-8978SP Frypot Assem bly, F u l l - V a t P r o t e c to r N a t u r a l 106-8979SP Frypot Assembly, F u l l - V a t P r o t e c t o r L P 2 106-9025SP Valve, Drain Assy .
2-17 2.8 Gas Supply and Combustion Sy stem Components FPGL30 Full Vat Gas Manifold (Typical) The example ill ustrated is typical of FPGL30 Protector ® Series Fryer Gas Manifold s. Each manifo ld is assembled from standard 1 /2-, 3/4-, and 1-inch NPT black iro n pipe nipples, elbo ws, tees, plugs, an d unions, which ma y be locally acquired.
2-18 2.8 Gas Supply and Combusti on System Components cont. ITEM PART # COMPONENT 1 Ignitor (includes gasket 816-0059, which may be ordered separately) 826-0981 Natural Gas (G20, G25) 826-0982 Propane.
2-19 2.9 Gas Valves and Associated Components.
2-20 2.9 Gas Valves and Associated Components cont. ITEM PART # COMPONENT 1 Valve, Non-CE Gas 826-1122 Natural Gas (G20, G25) 826-1120 Kit Natural Gas w/ flexlines and hardware 826-1123 Propane Gas (G.
2-21 2.10 Filtration System Components 5 4 3 2 1 6 10 12 13 14 15 16 8 18 17 7 17 10 11 19 15 20 9.
2-22 2.10 Filtration System Components cont. ITEM PART # COMPONENT 1 823-6616 Lid, Multi-Vat Fryers, Standard Size Filter Pan 823-6333 Lid, Two-Vat Fry er, Half Size Filter Pan 2 810-2874 Crumb Tray, Standard Size Filter Pan 3, 4 and 5 Vat 810-3288 Crumb Tray, Two-Vat Fry er, Half Size Filter Pan 3 810-2091 Hold-Down Ring 13.
2-23 2.11 Return Valve Assembly and Associated Parts ITEM PART # COMPONENT 106-8018 Valve, Return Assy . FV 1 810-2201 Valve, Return ½” Ball 2 902-2772 Handle, Right Valve 3 813-0165 Elbow, Street ½” x ½” NPT 90 ° BM 4 813-0087 Nipple, ½” x 1.
2-24 2.12 ATO (Auto Top-Off) Components 2.12.1 JIB (Jug In Box) Low Indicator Light Assembly ITEM PART # COMPONENT 1 106-8105SP Light, Yellow 24VDC LED Flush 2 230-4142 Bracket, Protector Light 2.
2-25 2.12.3 ATO (Automatic Top-Off) Solenoid and Pump Assemblies 6 1 2 3 4 5 7 9 8 ITEM PART # COMPONENT 1 106-9680SP Pump, ¼ FNPT 12VDC, 19PSI 15.1GPH 2 106-8477 Solenoid Manifold Assembly GL30-3 (i.
2-26 2.13 Wiring Connectors, Pin Terminals and Tools ITEM PART # COMPONENT 1 807-1068 2-Pin Female 2 807-0158 6-Pin Female 3 807-0156 9-Pin Female 5 807-0159 12-Pin Female 5 807-0875 15-Pin Female 6 8.
2-27 2.14 Fasteners ITEM PART # COMPONENT * 809-0429 Bolt, ¼-inch – 20 x 2.00-inch Hex Head ZP Tap * 809-0131 Bolt, ¼-inch -20 x ¾-inch Hex * 809-0953 Bolt, ¼-20 x ¾-inch Hex Head * 807-1926 Bushing, .875-inch Split * 809-0514 Capscrew, 5/16-inch-18 NC Hex * 809-0448 Clip, Tinnerman * 826-1351 Nut Retainer, ¼-20 (Pkg.
2-28 2.14 Fasteners cont. ITEM PART # COMPONENT * 809-0500 Screw, 10 x ½-inch Hex Washer Head 410 SS * 809-0434 Screw, 10 x ⅜ -inch Hex Washer Head NP * 809-0123 Screw, 10 x ¾-inch Slot Head * 826-1389 Screw, ¼-20 x ¾-inch Hex Head ZP (Pkg. of 10) (809-0131) * 826-1346 Spacer, Ignition Module (Pkg.
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Frymaster, L.L.C., 8700 Line Av enue, Shrev eport, Louisiana 71106 TEL 1-318-865-1711 FAX (Parts) 1-318- 219-7140 FAX (Tech Support) 1-318-219-7135 PRINTED IN THE UNITED STATES SERVICE HOTLINE 1-800-5.
An important point after buying a device Frymaster 8196345 (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 8196345 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 8196345 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Frymaster 8196345 you will learn all the available features of the product, as well as information on its operation. The information that you get Frymaster 8196345 will certainly help you make a decision on the purchase.
If you already are a holder of Frymaster 8196345, 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 8196345.
However, one of the most important roles played by the user manual is to help in solving problems with Frymaster 8196345. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Frymaster 8196345 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
