Frymaster Gas Rethermalizers FBKR18 Series manual

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 & FBKR18 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[...]

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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 ..................................................................................... 5-2 5.3 Replacing the Computer or Co mputer Wir[...]

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. Where conflicts exist between instructions and information in this manual and local or national codes of the country in wh ich the[...]

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. DANGER DANGER boxes contain information about actions or conditions that may cause or result in injury to personnel , [...]

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. QUALIFIED INST[...]

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. Conversion of this appliance from one ty[...]

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. The equipment flue opening must not be placed close to the[...]

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. In other countries, refer to the rating plate on the inside of the door for proper voltages. FCC [...]

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. Level rethermalizers equipped with legs by screwing out the legs approximately 1 inch then adjus[...]

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. DANGER When pressure-testing incoming gas supply lines, disconnect the appliance from the g[...]

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. Light the burners and perform the boil-out procedures th at are described in the “Start-[...]

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. Mechanically, the FBCR18 an[...]

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.) NOTE 1: The programm ing mode is not available while the computer is retherm[...]

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. The AutoFill will refill the cookpot with cold water. If desired, add ice [...]

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. Pressing the Simmer Mode ( R ) switch caus[...]

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. Next, press the Temperature Check/Program Lock switch to lo[...]

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. If a stir time exceeds the rethermalizing time, the stir alarm will not sound. 8. SELP (Select P[...]

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.  To toggle between Fahrenheit and Celsius temperature display , enter 1, 6, 5[...]

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 3.5, Boiling-Out the Cookpot. Before turning the rethermaliz[...]

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. To lessen the chance of boil over, turn the appliance’s gas valve knob to the PILOT position o[...]

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 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 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. 2. W[...]

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 may be straightened for[...]

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" W .C. 0.8 kPa LP 8.25" W . C. 2.5 kPa 4. If necessary, adjust the burner gas pressur[...]

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. DANGER This equipment should be unpl[...]

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. Open control panel by remov[...]

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. Refer t o troubles hooti ng guide "BU[...]

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. Is HEAT LED on interface board illuminated? Problem is with a failed inte[...]

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. W ait two mi nutes. Reconnect comput er wiring harness, close control panel , reconnect[...]

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. 3. Disconnect the wiring harness from the back of the computer. If replacing the harnes[...]

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. Two self-conta[...]

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. Although similar in appearance to standard Computer Magic III computers, the standard CM III computer[...]

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). The fourth LED is not lab[...]

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. 6.4 Checking the Burner Manifold G[...]

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. 5. Cut the tempera[...]

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. 3. Remove the component box cover by rem [...]

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. 5. Disconnect the wires from the gas valve terminal, m arking each wire to fac[...]

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. 3. Remove the flue cap and l[...]

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. A series of Troubleshooting Guides (de[...]

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. PROBLEMS RELATED TO THE GAS VALVE If the prob[...]

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. If the rethe[...]

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. Whatever the cause, the symptom is f[...]

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. W hat gas is the unit configured for? LP (Propane ) Natural Is incoming gas p[...]

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. Is c ombus tion air blower runing? Is 12V D[...]

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 HEAT J2 PIN 2 J2 PIN 4[...]

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. Is re[...]

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 29 136 1218 58 187 1324 86 238 142 8 114 35 1006 2 86 1114 30 137 1220 58 188 1326 87 239 143 0 115 36 1008 2 87 1116 31 138 1222 59 189 1328 87 240 143 2[...]

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 16C BLOWER BLUE BROWN 120 V 200-240V GREEN SWITCH 55C BLK 24V BLK 22C 6C WHT 23C LOAD LINE 32C 31C SOLENOID 8050875F LINE 12V 16 SOUND TEMP PROBE WHT 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 T URE PROBE K4 HEA T K3 LA TCH K5 J1 2 1 4 3 5 DN UP DN UP COM K2 K1 RIGHT PRODUCT BUTT ONS OPTIONAL BASKET LIFTS 120VAC IN 24VAC 24V WA TER HEAT LAT[...]

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, 3.26mm 810-0917 Propane Gas, 2.00mm 3 Ignitor and Insul[...]

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, Cover 4 910-5303 Bracket, Cover Support 5 823-2881 Flue Cap 6 900-5737 Back, Cabinet 7 900-7377 Side, Cabinet, CRS (for S/S units, use 910-7377) 8 900-52[...]

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. ITEM PART # COMPONENT * 106-0769 Computer, CM III (for use on FBCR18 Series retherm alizer only) * 806-9352 Computer, CM III (for use on FB[...]

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 (Propane) Gas (for bare cookpot only, order 823-4088SP) 2 900-5282 Cover, Front Insulation 3 816-0270 Insulation, Cookpot Front 4 816-0144 Insulation[...]

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 3 813-0154 Plug, Pipe, ⅛ ” Hex Head 4 813-0354 Elbow, ⅛ ” NPT x 90 ° x ⅛ ” Tube, Brass 5 813-0016 Nipple, ⅛ ” x ¾” NPT, BM 6 813-0004 Elb[...]

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 4.0”, Brass 5 813-0471 Nipple, ¼” x 1.5”, Brass 6 900-2916 Bracket, Water P[...]

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: $10.00 PRINTED IN THE UNITED STATES SERVICE HOTLINE 1-800-551-8633 819-5686 March 2005[...]