Frymaster FBR18 Series manual

Frymaster, a member of the Co mmercial Food Equipm ent Serv ice Association, recommends using CFESA Certified Tec hnicians. 819-5278 24-Hour Service Hotline 1-800-551-8633 May 2003 FBR18 & FBRA18 Series Gas Rethermalizers Installation, Operation, Service, and Parts Manual[...]

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. FUR THER, FRYMASTER/DEAN A[...]

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 ot[...]

i FBR18 & FBRA18 SERIES GAS RETHERMALIZERS TABLE OF CONTENTS CHAPTER 1: General Information 1.1 Parts Ordering and Service Information ............................................................................ 1-1 1.2 Safety Information ......................................................................................................... .[...]

ii Temperature Probe ............................................................................................................ 6 -3 Water Level Sensors (FBRA18 Only)............................................................................... 6-3 6.2 Accessing the Rethermalizer for Servicing ....................................................[...]

1-1 FBR18 & FBRA18 SERIES GAS RETHERMALIZERS CHAPTER 1: GENERAL INFORMATION 1.1 Parts Ordering and Service Information In order to assist you as quickly as possible, the Frymaster Factory Authorized Service Center (FASC) or Service Department representative requi res certain information about your equipm ent. Most of this information is printed[...]

1-2 CAUTION CAUTION boxes contain information about actions or conditions that may cause or result in a malfunction of your system . WARNING WARNING boxes contain information a bout actions or conditions that may cause or result in damage to your system , and which may cause your sy stem to malfunction. DANGER DANGER boxes contain information about[...]

1-3 QUALIFIED INSTALLATION PERSONNEL Qualified installation personnel are individuals, or fi rms, corporations, or companies which, either in person or through a representative, are engaged in a nd are responsible for the installation of electri- cal and gas appliances. Qualified personnel must be experienced in such work, be familiar with all elec[...]

2-1 FBR18 & FBRA18 SERIES GAS RETHERMALIZERS CHAPTER 2: INSTALLATION INSTRUCTIONS 2.1 General Installation Requirements PROPER INSTALLATION IS ESSENTIAL FOR E FFICIENT, TROUBLE-FREE OPERATION OF YOUR RETHERMALIZER. ANY UNAUTHORI ZED ALTERATIONS MADE TO THIS EQUIPMENT WILL VOID THE Frymaster WARRANTY. Upon arrival, inspect the rethermalizer care[...]

2-2 This equipment is manufactured to use the type of gas specified on the rating plate attached to the door. Connect equipment stamped “NAT” only to na tural gas and that stam ped “PRO” only to LP (Propane) gas. Installation shall be made with a gas connector th at com plies with national and local codes. Quick disconnect devices, if used,[...]

2-3 After the unit has been positioned in the area wher e it will be used, ensure the following has been accomplished before connecting the unit to the gas supply: 1. Adequate means must be provided to lim it the movem ent of this equipment without depending upon the gas line connections. If a flexible gas hose is used, a restraining cable must be [...]

2-4 2.4 Connecting to the Gas Supply GAS CONNECTIONS AND PIPE SIZES The size of the gas supply pipe is very important. If the pipe is too sm all, the gas pressure at the burner manifold will be low. This will cause slow recovery and delayed ignition. The incom ing gas supply line should be a minimum of 1½ inches (38mm) ID. When configured for natu[...]

2-5 WARNING “Dry-firing” this equipment will cause damage to the cookpot. Always ensure that the cookpot is filled with w ater before firing your unit. 4. It is suggested that the burner manifold pressu re be checked at this time by the local gas com - pany or an authorized service agent. Refer to “Check Burner Manifold Pressure” in Chapter[...]

3-1 FBR18 & FBRA18 SERIES GAS RETHERMALIZERS CHAPTER 3: OPERATING INSTRUCTIONS 3.1 Introduction Mechanically, the FBR18 and FBRA18 rethermalizer s are virtually identical, the only difference being that the FBRA18 units have an automatic filli ng (AutoFill) feature. Both units use the sam e digital temperature controller and mechanical tim ers.[...]

3-2 NOTE: The unit comes from the factory configured to display in degrees Fahrenheit. To toggle back and forth between Fahrenheit and Celsius, press the Celsius/Fahrenheit display switch. 2. The controller will automatically cycle the burne rs on and off seven times or until the tempera- ture in the cookpot reaches 160 ° F (71 ° C), whichever co[...]

3-3 1. Turn the gas valve to the ON position (see illustration below). OFF ON Hon e y w e l l 2. Press the controller Power switch. On FBR18 models , the burners will light for several sec onds then go out. A few seconds later they will light again. This cycle will repeat seven times or until the water in the cookpot reaches 160 ° F (71 ° C), whi[...]

3-4 4. After the solution simmers for an hour, turn the un it off, allow the solution to cool, then add 2 gallons (7.75 liters) of cold water and stir. Drain the solution and clean the cookpot thoroughly. 5. Rinse the cookpot at least twice by filling with clean water and draining. 6. Reprogram the setpoint to the appropriate temperature. 3.5 Shutt[...]

4-1 FBR18 & FBRA18 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 cords, leaks, foreign material in cookpot or inside cabinet, and any other indications that the rethermalizer and accessories are not ready and safe for [...]

4-2 4.2 Quarterly Checks and Services Check Digital Controller Set Point Accuracy 1. Fill the cookpot with water. Press the controller power switch. When the Heat Mode indicator (decimal between the first and second digits of the display) goes out, insert a good-grade thermometer or pyrom eter probe into the cookpot , with the end touching the temp[...]

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. Carefully unscrew the vent tube from the gas valv e. NOTE: The vent tube m ay be straightened fo[...]

4-4 3. Place the gas valve in the ON position. Place th e controller 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" W .C. 0.8 kPa LP 8.25" W . C. 2.5 kPa 4. If necessary, adjust the burner gas pres[...]

5-1 FBR18 & FBRA18 SERIES GAS RETHERMALIZERS CHAPTER 5: OPERATOR TROUBLESHOOTING 5.1 Introduction This chapter provides an easy reference guide to the more com mon problems that m ay occur during the operation of your equipment. The troubleshooting guides in this chapter are intended to help you correct, or at least accurately diagnose, problem[...]

5-2 5.2 Troubleshooting Guides COOKPOT DID NOT FILL WHEN UNIT WAS TURNED ON. WATER SUPPLY TO UNIT VERIFIED TO BE ON. Did anything appear in controller display when unit was turned on? Open control panel by removing screws in each upper corner. Is WATER LED on interface board illuminated? Probable causes are a failed water solenoid or a failed inter[...]

5-3 WATER DID NOT SHUT OFF WHEN COOKPOT WAS FULL. Use bottlebrush to clean water level sensors. Did water stop? Problem resolved. Add 1/8 cup of salt to water in cookpot and stir. Did water stop? Mineral content of water is insufficient for water sensor to detect it. Whenever cookpot is refilled, add 1/8 cup of salt. Open control panel by removing [...]

5-4 WATER NOT HEATING. AUTOFILL (IF INSTALLED) WORKED PROPERLY. Press the Temperature Check button twice to display setpoint. Has the correct setpoint been programmed? Did burners light? Did water reach setpoint temperature? Problem resolved. Insert a good grade thermometer into cookpot with tip near temperature probe and wait two minutes. Press th[...]

5-5 BURNERS DO NOT LIGHT. Verify that correct setpoint has been programmed, that main gas supply valve is open, and that equipment gas valve is set to ON. Press ON/OFF button. Did burners light? Problem resolved. Use bottlebrush to clean low water sensor. If burners still do not light, remove the cover over the water sensors and thoroughly clean th[...]

5-6 5.3 Replacing the Controller or Controller 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. 3. Disconnect the wiring harness from the back of th e controller. If replacing the[...]

6-1 Inside the Ignition Module TD Out to Gas Valve To A l a r m 25 V + 25 V GND HV Ignition Wire Flame Sensor Coil FBR18 & FBRA18 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 effi- ciency burner system requiring [...]

6-2 guished), current to the ignition module is cut, pr eventing the main valve from opening, and the igni- tion module “locks out” until the power switch is turned off and then back on. A probe monitors the temperature in the cookpot. W hen the programm ed setpoint temperature is reached, resistance in the probe causes the heat cycl e circuitr[...]

6-3 The relays in earlier design boards are soldered on and cannot be replaced. Later design boards fea- ture replaceable plug-in relays. In earlier designs boards, a heat relay (K2) switches 24VAC to the ignition and gas valve circuits when the controller h eat logic circuit calls for heat. Simultaneously, a blower motor relay (K4) switches 120VAC[...]

6-4 6.2 Accessing the Rethermalizer for Servicing DANGER Moving a rethermalizer filled with hot w ate r may cause spilling or splattering of the hot water. Alw ays drain the cookpot before attempting to relocate the unit for servic- ing. 1. Shut off the gas supply to the unit. Unplug the electrical power cord. Disconnect the unit from the gas suppl[...]

6-5 6.6 Replacing Components 6.6.1 Replacing the Controller or Controller Wiring Harness Refer to Chapter 5, Section 5.3 for this procedure. 6.6.2 Replacing the Temperature Probe 1. Unplug the rethermalizer and drain the cookpot. 2. Remove the screws from the upper corners of th e timer panel and swing the panel open from the top, allowing it to re[...]

6-6 5. On FBRA18 models only, mark the water level sens or wires and disconnect them from terminals J1-1 (upper sensor) and J1-2 (lower sensor). 6. Remove the nuts in each corner of the interface board and carefully pull the board off the m ount- ing studs, being careful not to dislodge the spacers on the studs. 7. Position the replacement board on[...]

6-7 6.6.6 Replacing the Combustion Air Blower Refer to Chapter 4, Section 4.4, Clean Combustion Air Blower , for instructions on removing and re- installing the combustion air blower. 6.6.7 Replacing the Gas Valve 1. Turn off the gas supply to the rethermalizer, unplug the unit, and drain the cookpot. 2. Disconnect the unit from the gas supply line[...]

6-8 4. Remove the four screws from the blower stabilizi ng bracket attached to the blower assembly and to each burner. Remove the stabilizing bracket from the unit. 5. Remove the screw securing the blower support br acket to the cookpot assembly and lower the blower assembly out of the way. It is not necessary to disconnect the blower wiring. 6. Re[...]

6-9 knowledge of possible problems, and the probable cau ses of each. W ith this knowledge, the techni- cian should be able to isolate and correct any problem encountered. 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. Contr[...]

6-10 tion failure situation may be encountered in which all com ponents 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 inte rmittent failure of an i gnition module. When the unit is opened up for troubleshooting, [...]

6-11 If popping is consistent during all hours of operation, the most likely cause is an insufficient air sup- ply. Check for “negative pressure” conditions in the kitchen area. If air is flowing into the kitchen area, this indicates that more air is being exhaus ted than is being replenished, and the burners may be starved for air. If the reth[...]

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 temper ature probe. Other components include the inter- face board, the water level sensors (on FBRA18 units ), the controller, and the ignition module. Whatever the cau[...]

6-13 6.8.1 Troubleshooting the Gas Valve NOTE: All voltage measurements must be made within 4 seconds of unit calling for heat. If unit does not fire within 4 seconds, ignition modules will lock out and controller must be turned off then back on to reset. MAIN GAS SUPPLY VALVE VERIFIED TO BE OPEN AND EQUIPMENT GAS VALVE IN ON POSITION. Is there 24V[...]

6-14 6.8.2 Troubleshooting the 24 VAC Circuit in FBR18 Units NOTE: All voltage measurements must be made within 4 seconds of unit calling for heat. If unit does not fire within 4 seconds, ignition modules will lock out and controller must be turned off then back on to reset. UNIT IS CONNECTED TO POWER SUPPLY, DRAIN VALVE IS FULLY CLOSED, CONTROLLER[...]

6-15 THE 24 VAC CIRCUIT IN FBR18 UNITS 24V TRANSFORMER BLOWER CENTRIFUGAL SW ITCH RIGHT IGNITION MODU LE LEFT IGNITION MODU LE GAS VALVE J3 PIN 8 LED 3 (24V) RELAY K2 ON EARLY DESIGN BOARD S OR REL AY K3 O N LA TER DE SIGN B OARD S LED 4 (PW R ) RIGHT PW R TERMINAL J2 PIN 7 J2 PIN 5 V1S TERMINAL LED 2 (PW R) LEFT PW R TER MINAL J2 PIN 2 LED 5 (GV) [...]

6-16 6.8.3 Troubleshooting the 24 V AC Circuit in FBRA18 Units UNIT IS CONNECTED TO POWER SUPPLY, DRAIN VALVE IS FULLY CLOSED, NO WATER IS IN POT, CONTROLLER IS ON. Is POWER LED lit? Is WATER LED lit? Is unit filling with water? Once water reaches upper water level sensor, does filling stop and WATER LED go out? Water leg of 24V circuit is OK. Is W[...]

6-17 6.8.3 Troubleshooting the 24 VAC Circ uit in FBRA18 Units (Continued) NOTE: All voltage measurements involving the gas valve leg of the 24V circuit must be made within 4 seconds of unit calling for heat. If unit does not fire within 4 seconds, ignition modules will lock out and controller must be turned off then back on to reset. A Is 24VAC pr[...]

6-18 6.8.3 Troubleshooting the 24 VAC Circ uit in FBRA18 Units (Continued) NOTE: All voltage measurements involving the gas valve leg of the 24V circuit must be made within 4 seconds of unit calling for heat. If unit does not fire within 4 seconds, ignition modules will lock out and controller must be turned off then back on to reset. B Is 24VAC pr[...]

6-19 6.8.3 Troubleshooting the 24 VAC Circ uit in FBRA18 Units (Continued) NOTE: All voltage measurements must be made within 4 seconds of unit calling for heat. If unit does not fire within 4 seconds, ignition modules will lock out and controller must be turned off then back on to reset. C Is 24VAC present on J1 pin 5 when unit calls for heat? Is [...]

6-20 THE 24VAC CIRCUIT IN FBRA18 UNITS 24V TRANSFORM ER J2 P IN 4 LED POW ER LATC H RELAY INTERFACE BOARD LOGIC C IRCUITRY J2 P IN 3 J2 PIN 2 J1 P IN 3 LED WA T E R WAT ER SOLENOID VALVE J2 PIN 1 WAT ER RELAY K2 BLOWER CENTRIF UGAL SWI TCH RIGHT IGN ITIO N MODUL E LEFT IGN ITIO N MODUL E GAS VALVE CYCLE RELAY K1 LED CYCLE W IRING HARNESS PIN 4 W IR[...]

6-21 6.8.4 Troubleshooting the Temperature Probe W HILE IT IS STIL L IN THE COOKPOT, INSPEC T THE PR OBE BODY FO R DA MAG E . REPL ACE IF BENT, DENTED, OR CRA CK E D. Inspe ct lead s for fraying, burning, breaks, and/or kinks. If found, rep l ac e prob e. Dete rmine te mpera ture of w ater in co okpot using a t h erm om eter or pyrometer placed at [...]

6-22 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 1424 113 33 1002 1 84 1110 29 135 1216 57 186 1322 86 237 1426 114 34 1004 1 85 1112 29 136 1218 58 187 1324 86 238 1428 114 35 1006 2 86 1114 30 137 1220 58 188 1326 87 239 1430 115 36 1008 2 87 1116 31 138 1222 59 189 1328 87 240 1432 116 [...]

6-23 6.9 Wiring Diagram for FBR18 Units 5 81 1 10 12 9 7 6 4 3 1 2 GND GND 3 2 1 SOUND GND V1S ALRM PWR V1D GND GND V2S A S A D PWR V2D GND GREEN J2 10 11 12 CENT. SWITCH C NC NO J3 1C 3C 8C 56C 5C 2C 22C 21C 55C 17C 16C 60C 53C 42C 7C 12C 14C 19C 18C 44C 43C * * 10C 111C 9C 49C 11C 51C 13C 36C 101C 23C 4C 123456789 12C 111C 2C (WHT) (BLK ) (ORN) ([...]

6-24 6.10 Wiring Diagram for FBRA18 Units IGNITOR IGNITION MODULE GAS VALVE HIGH VOLTAGE LEAD. AS ITS MATCH I N G TO THE S AME IG NITOR MUST BE CO NNECTED FLAME SENSOR WI R E NOTE : WIRE TEMP HIGH IGNITION MODULE IGNITOR TEMP WIRE HIGH ORANGE LEFT I GNITIO N 25V GND 25V BLOWER J3 2 1 120 V SWI TCH (BURNER) VALVE ALARM GND RIGHT IGNITION 25V 25V GND[...]

7-1 FBR18 & FBRA18 SERIES GAS RETHERMALIZERS CHAPTER 7: PARTS LIST 7.1 Burner System Components 1 2 3 4 5 6 ITEM PART # COMPONENT Burner Assemblies 806-5563 Natural Gas, Complete 806-5564SP Propane Gas, Complete 1 810-1382 Burner, Reverse Plenum, Universal 2 Orifice 810-0916 Natural Gas, 3.26mm 810-0917 Propane Gas, 2.00mm 3 Ignitor 810-0521 Na[...]

7-2 7.2 Cabinetry and Associated Components 1 2 3 4 5 6 7 8 10 9 14 15 11 12 13 16 21 17 18 19 20 22 ITEM PART # COMPONENT 1 910-1181 Retainer , Flue Ca p Insulation 2 816-0157 Insulation, Flue 3 900-4603 Flue Guar d 4 823-2107 Flue Ca p 5 810-2263 Han g er, Basket ( re p laced extruded aluminum han g e r , no lon g er available ) 6 910-7434 To p C[...]

7-3 7.3 Control Box Assembly and Asso ciated Parts, FBR18/ FBRA18 BLACK WHITE LEFT IGNITOR RIGHT IGNIT OR 5 6 7 84 3 2 1 25V (GND) ALARM VALVE GND (BURNER) 25V 25V (BURNER) GND VALVE ALARM (GND) 25V LOAD LINE 12 120 120 24 LINE LOAD GREEN 5 4 4 2 RIGHT LEFT 7 6 8 10 9 9 2 3 1 ITEM PART # COMPONENT 1 900-4509 Control Box Mounting Base 2 807-1006 Ign[...]

7-4 7.4 Controller and Component Box Assemblies GND GND SOUND 1 2 GND 2 1 3 4 6 7 91 2 10 11 8 5 1 3 2 6 4 5 9 7 8 12 10 11 J3 Fryma ste r - - - - C F 1 2 4 5 7 3 3 8 GND 3 J1 GND V1D PWR ALR M V1S GND V2D PW R A D A S V2S FBR18 Component Box 6 FBRA18 Component Box Controller ITEM PART # COMPONENT 1 824-0396 Control Box (used on FBR18 only) 2 806-3[...]

7-5 7.5 Cooking Timer Control Panel Components Error! Not a valid link. ITEM PART # COMPONENT 1 910-4496 Cooking Timer Control Panel 2 Knob Assembly 810-1287 Black 806-5339 Gray 806-5340 Red 806-5341 Brown 806-5342 Blue 806-5343 Green 3 810-0808 Faceplate, Timer Dial 4 810-0807 Timer, Springwound, 60-Minute 5 807-1547 Lamp, Red Lens, 24V Trouble 6 [...]

7-6 7.6 Cookpot, FBR18 6 7 8 9 10 1 2 3 4 5 ITEM PART # COMPONENT 1 900-1762 Retainer, Insulation 2 900-7431 Cover, Cookpot Front Insulation 3 816-0143 Insulation, Cookpot Front 4 823-1891SP Cookpot 5 816-0144 Insulation, Cookpot Side 6 806-5251SP Probe Assembly, Temperature 7 824-0395 Guard, Probe 8 900-1031 Retainer, Sight Glass 9 816-0053 Insula[...]

7-7 7.7 Cookpot, FBRA18 8 9 10 11 12 13 This washer must be seated in ho le before nut is tightened. Torque nut to 30 in-lb ± 5. Inside face o f cookpot. Enlarged View of Water Level Sensor Assembly 7 1 2 3 4 6 5 ITEM PART # COMPONENT 1 900-1762 Retainer, Insulation 2 900-7431 Cover, Cookpot Front Insulation 3 816-0143 Insulation, Cookpot Front 4 [...]

7-8 7.8 Gas Supply Components 15 14 13 12 11 10 1 2 3 4 5 6 7 9 8 ITEM PART # COMPONENT 1 Gas Valve 810-0786 Natural Gas 810-0787 LP (Propane) Gas 2 813-0378 Fitting, Cross, ⅛ ” NPT, Brass 3 813-0154 Plug, Pipe, ⅛ ” Hex Head 4 813-0340 Adapter, ⅛ ” NPT x ⅛ ” Tube, Brass 5 813-0016 Nipple, ⅛ ” x ¾” NPT, BM 6 813-0004 Elbow, ?[...]

7-9 7.9 Plumbing Components 5 1 6 7 3 4 10 2 8 9 12 11 13 16 15 14 17 20 18 19 ITEM PART # COMPONENT 1 806-9067 Valve Assembly, Solenoid (FBRA18 only) 2 810-1208 Valve, Water Pressure Regulator (FBRA18 only) 3 900-2916 Bracket, Water Pressure Regulator Valve (FBRA18 only) 4 813-0448 Elbow, Pipe Fitting, Brass, ¼” (FBRA18 only) 5 813-0302 Elbow, [...]

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Frymaster, L.L.C., 8700 Line Av enue, PO Box 51 000, 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: $10.00 PRINTED IN THE UNITED STATES SERVICE HOTLINE 1-800-551-8633 819-5278 May 2003[...]