Instruction/ maintenance manual of the product Gas Rethermalizers FBKR18 Series Frymaster
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Frymaster, a member of the Co mmercial Food Equipment Serv ice Association, recommends using CFESA Certified Tech nicians. 819-5686 24-Hour Service Hotline 1-800-551-8633 March 2005 FBCR18 & FBKR1.
NOTICE IF, DURING THE WARRANTY PERIOD, THE CUST OMER USES A PART FOR THIS ENODIS EQUIPMENT OTHER TH AN AN UNMODIFIED NEW OR RECYCLED PART PURCHASED DIRECTLY FROM FR YMASTER/DEAN, OR ANY OF ITS AUTHORIZED SERVIC E CENTERS, AND/OR THE PART BEIN G USED IS MODIFIED FROM ITS ORIGINAL CONFIGURATION, THI S WARRANTY WILL BE VOID.
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i FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS TABLE OF CONTENTS CHAPTER 1: General Information 1.1 Parts Ordering and Service Information ............................................................................ 1-1 1.2 Safety Information .......
ii CHAPTER 5: Operator Troubleshooting 5.1 Introduction ............................................................................................................... ........ 5-1 5.2 Operator Troubleshooting Guides ..................................
1-1 FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS CHAPTER 1: GENERAL INFORMATION 1.1 Applicability and Validity This manual is applicable to and valid for all FBCR18 and FBKR18 units sold in English- speaking countries.
1-2 1.3 Safety Information Before attempting to operate your unit, read the instructions in this manual thoroughly. Throughout this manual, you will find safety notati ons enclosed in double-bordered boxes similar to the one below.
1-3 1 .6 Definitions QUALIFIED AND/OR AUTHORIZED OPERATING PERSONNEL Qualified/authorized operating personnel are those w ho have carefully read the information in this manual and have fam iliarized themselves with the equipment functions, or who have had previous experience with the operation of the equipment covered in this manual.
2-1 FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS CHAPTER 2: INSTALLATION INSTRUCTIONS 2.1 General Installation Requirements Qualified, licensed, and/or authorized installati on or service personnel, as defined in Section 1.6 of this manual, should perform all installation and service on Frymaster equipment.
2-2 One of the most important considerations of effi cient operation is ventilation. Make sure the equip- ment is installed so that products of combustion are rem oved efficiently, and that the kitchen ventila- tion system does not produce drafts that interfere with proper burner operation.
2-3 All electrically operated appliances must be grounde d in accordance with all applicable national and local codes. A wiring diagram is located on the insi de of the door. In the United States and Canada, the electrical supply must be 120VAC, 60 Hz.
2-4 2. The rethermalizer must be stabilized by insta lling restraining chains on units equipped with casters or anchor straps on units equipped with legs. Follow the instructions shipped with the casters/legs to properly install the chains or straps. 3.
2-5 2.4 Connecting to the Gas Supply DANGER Before connecting new pipe to this applia nce, the pipe must be blown out thor- oughly to remove all foreign material. For eign material in the burner and gas con- trols will cause improper and dangerous operation.
2-6 2. Open the gas supply to the fryer and check all pi ping, fittings, and gas connections for leaks. A soap and water solution should be used for this purpose. 3. Close the drain valve and fill the cookpot with wa ter and boil-out solution to the overflow.
3-1 FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS CHAPTER 3: OPERATING INSTRUCTIONS 3.1 Introduction WARNING The on-site supervisor is responsible for ensuring that operators are made aware of the inherent hazards of operating a gas-fire d heated water system, particularly the aspects of draining and cleaning procedures.
3-2 P ROGRA MMING THE FBCR18 S ERIES C OMPUTER 1. Turn the computer on by pressing the Power switch. 2. Press the Program Mode switch. CodE appears in the left display. Press, in sequence, product buttons 1, 6, 5, and 10. (Press switch again to exit the programming m ode.
3-3 If you rethermalize more food than you use, use th e chill feature to quickly reduce the temperature of the food before refrigerating or freezing. 1. Press the Chill Mode switch to de-energize the heating elements. 2. Open the drain valve and drain most of the hot water.
3-4 Pressing the Boil Mode ( L ) switch overrides the programmed setpoint and the cookpot tem perature rises to boiling at 212 ° F (100 ° C). When the unit is in boil mode, boiL appears in both LED displays. The unit remains in boil mode until th e Simmer Mode switch is pressed or the unit is turned off.
3-5 NOTE 1: Programming m ode is not available while the computer is rethermalizing; the display will flash BUSY . NOTE 2: To toggle between Fahrenheit and Celsius temperature display, press the Program Mode switch, then enter the code 1 6 5 8 by pressing the corresponding product buttons.
3-6 Remember: Stir time 2 must be greater than st i r t i m e 1 ( o r e ls e be “ 0 ” ). S ti r ti m e 3 must be greater than stir time 2 (or else be “0”). None of the stir times should be greater than the rethermalizing time entere d in Step 6.
3-7 To change the temperature display, press the Program Mode switch; CodE appears in the display. To toggle constant temperature display on and off, enter 1, 6, 5, 1, . NOTE: W h e n i n constant temperature display mode, the countdown tim e will not be displayed.
3-8 3.4 Start-Up Procedure (Applies to both the FBCR18 and FBKR18) WARNING Never operate this appliance with an em pty cookpot. The cookpot must be filled with w ater before lighting the burners. CAUTION If this is the first time the unit is being used after installation, refer to Section 3.
3-9 3.5 Boiling-Out the Cookpot DANGER Never leave the appliance unattended during th e boil-out process. If the boil-out so- lution boils over, turn the appliance off i mmediately and let the solution cool for a few minutes before resuming the process.
4-1 FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS CHAPTER 4: PREVENTIVE MAINTENANCE 4.1 Daily Checks and Services Inspect Rethermalizer and Accessories for Damage Look for loose or frayed wires and co.
4-2 4.2 Quarterly Checks and Services Check Computer Magic III Set Point Accuracy 1. Fill the cookpot with water. Press the computer power switch, and then press any of the product buttons. Insert a good-grade thermometer or pyr om eter probe into the cookpot, with the end touching the temperature probe at the lower right front of the cookpot.
4-3 open or close the air intake opening until a bright orange-red glow is obtained. Carefully hold the plate in position and retighten the nut(s). Clean Gas Valve Vent Tube 1. Set the rethermalizer power switch and the gas valve to the OFF position. 2.
4-4 3. Place the gas valve in the ON position. Place the computer power switch in the ON position. When the burner lights and continues to burn, co m pare the indicated pressure to the table below. Burner M anifold G as Pressures Gas Pressure Natural 3.
5-1 FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS CHAPTER 5: OPERATOR TROUBLESHOOTING 5.1 Introduction DANGER Water heated to cooking/rethermalizing temperature will cause severe burns. Never attempt to move this applian ce when filled w ith heated water or to transfer heated water from one container to another.
5-2 5.2 Troubleshooting Guides COOKP OT DI D NOT F I L L WH E N U NI T WAS TURNED ON . W ATER SUPPLY TO UNIT VERIFIED TO BE ON. Did anythi ng appear in CM III dis play whe n u n it wa s turned on? Comput er is not funct ioning. Probable caus es are fail ed 12V transform er, f ailed interf ace board, or failed c omput er.
5-3 WA TE R NO T HEATING. AUTOFILL W ORKED PROPERLY. Press th e Temperature Check b utton twice to display setpoint. Is the displayed setp oint corr ect? Enter cor rect setpoin t in accor dance with instru cti ons in Chapt er 3. Did burners light ? Did water reach s etpoint tem perature? Problem resol ved.
5-4 BURNERS DO NOT LIGHT. Verify that corr ect setpoint has been programmed, that m ain gas supply valve is open, and that equipment gas valve is set to ON. Press ON/OFF butt on. Did burners light? Problem resolved. Open control panel by removing sc rews in each upper corner.
5-5 CM III W ILL NOT G O INTO PROGRAMMING MODE OR DOES NO T ACCEPT CH ANG ES TO PR OGRAM . Press Pow er Sw itch OFF, disconnec t unit from electrical power, open control panel by removing s crews in upper corners, and unplug wiring harness from interfac e board.
5-6 5.3 Replacing the Computer or Computer Wiring Harness 1. Disconnect the rethermalizer from the electrical supply. 2. Remove the two screws in the upper corners of the control panel and swing the panel open from the top, allowing it to rest on its hinge tabs.
6-1 FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS CHAPTER 6: SERVICE PROCEDURES 6.1 Functional Description These rethermalizers contain a welded stainless steel cookpot that is directly heated by a high efficiency burner system requiring approximately 43% less energy than conventional burner system s to heat the same volume of water.
6-2 TD Out to Gas Valve To Alarm 25 V + 25 V GND HV Ignition Wire Flame Sensor Coil Inside the Ignition Module COMPUTERS These rethermalizers are equipped with Computer Ma gic III com puters that have been modified for this specialized application.
6-3 solenoid valve when the water level reaches the upper water level sensor and to de-energize the solenoid when the water level drops below the upper water level sensor. The board has four LEDs to assist in troubles hooting. Three of the LEDs (LATCH, WATER, and HEAT) are located just to the right of the heat re lay (K4).
6-4 3. Relocate the rethermalizer for service accessibility. 4. After servicing is complete, reconnect the unit to the gas supply, reattach restraining devices, and plug in the electrical power cord. 6.3 Cleaning the Gas Valve Vent Tube Refer to Semi-Annual Checks and Services in Chapter 4, Preventive Maintenance.
6-5 6.6.2 Replacing the Temperature Probe 1. Unplug the rethermalizer. 2. Drain the cookpot. 3. Remove the screws from the upper corners of the control panel and swing the panel open from the top, allowing it to rest on its hinge tabs. 4. Remove the cover from the com ponent box by removing the three screws along its bottom edge.
6-6 10. Reattach the 15-pin connector to the interface board. 11. Close and secure the control panel. 6.6.4 Replacing an Ignition Module 1. Unplug the rethermalizer. 2. Remove the screws from the upper corners of the control panel and swing the panel open from the top, allowing it to rest on its hinge tabs.
6-7 2. Disconnect the unit from the gas supply line and remove any fitting that m ay be attached to the gas manifold at the rear of the unit. 3. Disconnect the flexible gas lines at each burner orifice. 4. Disconnect the gas enrichment tubes at the gas valve tee fitting.
6-8 7. Reverse steps 1-6 to install replacement burner a ssembly, being careful to get the insulation strip running along the top of the blower support bracket back in place. 6.6.9 Replacing the Cookpot 1. Remove the cookpot insert. 2. Remove the top cap by removing the two screws on the front and the screw on each end.
6-9 Problems that are likely to be encountered can be grouped into five broad categories: 1. Ignition failures 2. Improper burner functioning 3. Improper temperature control 4. Computer-related problems 5. Autofill System problem s. The probable causes of each category are discusse d in the following sections.
6-10 during operation. The probable cause in this case is an intermittent failure of an ignition m odule. When the unit is opened up for troubleshooting, th e m odule cools down enough to operate correctly, but when the unit is again closed up and placed back into service, the module heats up and fails.
6-11 If popping is consistent during all hours of operati on, 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 be ing exhausted than is being replenished, and the burners may be starved for air.
6-12 6.7.3 Improper Temperature Control Temperature control is a function of several inte rrelated com ponents, each of which must operate correctly. The principle component is the te mp erature probe. Other components include the interface board, the water level sensors, the comput er, and the ignition m odule.
6-13 6.8.1 Troubleshooting the Gas Valve MAIN GAS SU PPLY VALVE VERIFIED TO BE OPEN AN D EQUIPM ENT GAS VALVE IN ON POSITION. Is 24VAC present on the main coil (PV terminal) of the gas valve? Problem is with the 24VAC circuit. Re fer to Troubleshooting the 24VAC C ircuit.
6-14 6.8.2 Troubleshooting the 24 VAC Circuit W ATER LE VEL IN COOKPOT IS ABOVE L OWE R WA T ER LEVEL SENSOR AND COMPUTER IS ACTIVATED. Is 24V AC present o n J2 Pin 7? Probable c ause is a failed trans former. Is LATCH LED illum inated? Probable caus e is fail ed com puter or failed 15-pin wiring harness.
6-15 THE 24VAC CIRCUIT 24V LEG OF DUAL VOLT AGE TRANSFOR MER K3 K6 K4 WA T E R SOLE NOI D VALVE GAS VALVE BLOWER CENTRIF UGAL SW ITCH LEFT IGNITION MODULE RIGHT IGNITION MODULE LED J2 PIN 7 W ATER HEA.
6-16 6.8.3 Troubleshooting the Temperature Probe W HILE IT IS STILL I N THE COOKPOT, INSPECT TH E PROBE BODY FOR D AMAGE. REPLACE IF BENT, DENTED , OR CRACKED. Inspect leads for fraying, burning, breaks, and/or kinks . If found, replace probe. Determine t emperature of water in cookpot using a thermom eter or pyrometer placed at tip of probe.
6-17 F O H M SC F O H M SC F O H M SC F O H M SC F O H M SC 32 1000 0 83 1107 28 134 1214 57 185 1320 85 236 142 4 113 33 1002 1 84 1110 29 135 1216 57 186 1322 86 237 142 6 114 34 1004 1 85 1112 29 1.
6-18 6.9 Simplified Wiring Diagrams (FBKR18 ONLY).
6-19 IGNITOR GAS VALVE TO THE SAME IGNITOR. & SPARK 2 MUST CONNE CT SAME IGNITOR. SENSE 2 MUST CONNECT TO T HE 16C SENSE 1 & SPARK 1 NOTE: WIRE TEMP HIGH 55C 43C IGNITOR ORG IGNITION M ODULE 1.
6-20 24VAC 24VA C 11 10 14 13 9 7 LEFT PRODUCT BUTTONS J4 1 12 4 2 7 9 3 10 11 J2 Q3 K6 WA T E R 1 5 3 ON/OFF 4 6 8 Q2 U2A U2D U2B U2C J3 COMPUTER INTERFACE BOARD 806- 9295 LOW WA T E R SENSOR TEMPERA.
7-1 FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS CHAPTER 7: PARTS LIST 7.1 Burner System Components 1 3 5 4 2 ITEM PART # COMPONENT Burner Assemblies 806-5563 Natural Gas, Complete 806-5564SP Propane Gas, Com plete 1 810-1382 Burner, Reverse Plenum , Universal 2 Orif ice 810-0916 Natural Gas, 3.
7-2 7.2 Cabinetry and Associated Components 1 2 3 4 16 17 18 19 20 5 6 7 8 9 11 10 15 14 13 12 ITEM PART # COMPONENT 1 806-8060 Cover Assembly w/Handle 2 810-1374 Handle, Cover 3 910-5246 Bracket, Cov.
7-3 7.3 Computer, Component Box Assembly, and Associated Parts 6 2 1 INTERFACE BOARD MOUNTS ON THESE STUDS 29C 8C 2C 5C 4C 9C 7C 3 4 5 7 Pin 1 8 NOTE: Components a re not drawn to scale relativ e to each other.
7-4 7.4 Cookpot and Associated Parts ITEM PART # COMPONENT 1 Cookpot Assembly (includes flue, insulation, burners and blower) 106-2792 Natural Gas (for bare cookpot only, order 823-4088SP) 106-2793 LP.
7-5 7.5 Gas Supply Components 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 ITEM PART # COMPONENT 1 Gas Valve 810-0786 Natural Gas 810-0787 LP (Propane) Gas 2 813-0378 Fitting, Cross, ⅛ ” NPT, Brass 3 813-0.
7-6 7.6 Plumbing Components 18 13 14 15 16 12 19 17 NOTE: Val ve handle nut come s with valve. 5 3 4 2 8 1 7 6 9 11 10 ITEM PART # COMPONENT 1 810-1208 Valve, Water Pressure Regulator 2 810-1351 Vacuum Breaker 3 813-0448 Elbow, ¼”, Brass 4 813-0473 Nipple, ¼” x 4.
Frymaster, L.L.C., 8700 Line Av enue, PO Box 51000, Shreveport, Louisiana 71135-1000 Shipping Address: 8700 Line Av enue, Shreveport, Louisiana 71106 TEL 1-318-865-1711 FAX (Parts) 1-318- 219-71 40 FAX (Tech Support) 1-318-219-7135 Price: $10.
An important point after buying a device Frymaster Gas Rethermalizers FBKR18 Series (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 Gas Rethermalizers FBKR18 Series 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 Gas Rethermalizers FBKR18 Series - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Frymaster Gas Rethermalizers FBKR18 Series you will learn all the available features of the product, as well as information on its operation. The information that you get Frymaster Gas Rethermalizers FBKR18 Series will certainly help you make a decision on the purchase.
If you already are a holder of Frymaster Gas Rethermalizers FBKR18 Series, 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 Gas Rethermalizers FBKR18 Series.
However, one of the most important roles played by the user manual is to help in solving problems with Frymaster Gas Rethermalizers FBKR18 Series. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Frymaster Gas Rethermalizers FBKR18 Series 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
