Frymaster 8196203 Users Manual Navy Surface Ship Electric IOSP Front Cover
H14SC 819-6203 NOV 08
8196203 to the manual f5f2735e-9f36-4230-b763-023b972f3c47
2015-02-09
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NAVY SURFACE SHIP ELECTRIC FRYERS Installation, Operation, Service, and Parts Manual H14SC/H17SC/H22SC Single Fryers, FPH17SC Series Filtration System Fryers This manual is applicable to fryers manufactured beginning May 2006 with serial numbers beginning with 0604. For serial numbers between 0308 to 0604 refer to manual 819-6004. For serial numbers prior to 0308, refer to manual 819-5184. Frymaster, a member of the Commercial Food Equipment Service Association, recommends using CFESA Certified Technicians. 24-Hour Service Hotline 1-800-551-8633 www.frymaster.com E-mail: service@frymaster.com NOV 08 *8196203* NOTICE IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART FOR THIS ENODIS EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART PURCHASED DIRECTLY FROM FRYMASTER DEAN, OR ANY OF ITS AUTHORIZED SERVICE CENTERS, AND/OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL CONFIGURATION, THIS WARRANTY WILL BE VOID. FURTHER, FRYMASTER DEAN AND ITS AFFILIATES WILL NOT BE LIABLE FOR ANY CLAIMS, DAMAGES OR EXPENSES INCURRED BY THE CUSTOMER WHICH ARISE DIRECTLY OR INDIRECTLY, IN WHOLE OR IN PART, DUE TO THE INSTALLATION OF ANY MODIFIED PART AND/OR PART RECEIVED FROM AN UNAUTHORIZED SERVICE CENTER. DANGER Copper wire suitable for at least 167°F (75°C) must be used for power connections. DANGER The electrical power supply for this appliance must be the same as indicated on the rating and serial number plate located on the inside of the fryer door. DANGER This appliance must be connected to the voltage and phase as specified on the rating and serial number plate located on the inside of the fryer door. DANGER All wiring connections for this appliance must be made in accordance with the wiring diagrams furnished with the equipment. Wiring diagrams are located on the inside of the fryer door. DANGER Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. NOTICE Drawings and photos used in this manual are intended to illustrate operational, cleaning and technical procedures. They may differ slightly in appearance or placement between fryers but functionality should remain the same. They may not conform to onsite management operational procedures. WARNING Frymaster fryers equipped with legs are for permanent installations. Fryers fitted with legs must be lifted during movement to avoid damage and possible bodily injury. For a moveable or portable installation, Frymaster optional equipment casters must be used. Questions? Call 1-800-551-8633 or email at service@frymaster.com DANGER The front ledge of the fryer is not a step. Do not stand on the fryer. Serious injury can result from slips or contact with the hot oil. DANGER All wiring connections for this appliance must be made in accordance with the wiring diagrams furnished with the equipment. Wiring diagrams are located on the inside of the fryer door. WARNING This equipment is intended for indoor use only. Do not install or operate this equipment in outdoor areas. NOTICE This appliance is intended for professional use only and is to be operated by qualified personnel only. A Frymaster DEAN Factory Authorized Service Center (FASC) or other qualified professional should perform installation, maintenance, and repairs. Installation, maintenance, or repairs by unqualified personnel may void the manufacturer’s warranty. NOTICE This equipment must be installed in accordance with the appropriate national and local codes of the country and/or region in which the appliance is installed. NOTICE TO U.S. CUSTOMERS This equipment is to be installed in compliance with the basic plumbing code of the Building Officials and Code Administrators International, Inc. (BOCA) and the Food Service Sanitation Manual of the U.S. Food and Drug Administration. WARNING 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. NOTICE TO OWNERS OF UNITS EQUIPPED WITH COMPUTERS U.S. This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: 1) This device may not cause harmful interference, and 2) This device must accept any interference received, including interference that may cause undesired operation. While this device is a verified Class A device, it has been shown to meet the Class B limits. CANADA This digital apparatus does not exceed the Class A or B limits for radio noise emissions as set out by the ICES-003 standard of the Canadian Department of Communications. Cet appareil numerique n’emet pas de bruits radioelectriques depassany les limites de classe A et B prescrites dans la norme NMB-003 edictee par le Ministre des Communcations du Canada. 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. 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 soaking in certain shortening material. WARNING Do not bang fry baskets or other utensils on the fryer’s joiner strip. The strip is present to seal the joint between the frypots. Banging fry baskets on the strip to dislodge shortening will distort the strip, adversely affecting its fit. It is designed for a tight fit and should only be removed for cleaning. WARNING Never spray the fryer with water or use water jets to clean the fryer. Navy Surface Ship Electric Fryers Installation, Operation, Service, and Parts Manual TABLE OF CONTENTS Page Chapter 1: Introduction 1-1 Chapter 2: Installation Instructions 2-1 Chapter 3: Operating Instructions 3-1 Chapter 4: Filtration Instructions 4-1 Chapter 5: Preventive Maintenance 5-1 Chapter 6: Operator Troubleshooting 6-1 Chapter 7: Service Procedures 7-1 Chapter 8: Parts List 8-1 i NAVY SURFACE SHIP ELECTRIC FRYERS CHAPTER 1: INTRODUCTION 1.1 General Read the instructions in this manual thoroughly before attempting to operate this equipment. This manual covers all configurations of Navy Surface Ship Electric Fryer models specifically configured for use aboard surface ships of the U.S. Navy, including H14SC/H17SC/H22SC kW and FPH17SC kW filtration system models. The fryers in this model family have most parts in common, and when discussed as a group, will be referred to as “Navy Surface Ship Electric” fryers. Although similar in appearance to the Footprint Pro family of Navy Electric fryers, the Navy Surface Ship Electric fryers feature a significantly different rotating element assembly. Other features, including the deep cold-zones, open frypots and filtration systems remain essentially unchanged. All Navy fryers are equipped with solid-state analog controllers. Fryers in this series can be single units or grouped in batteries of two or more fryers. 1.2 Safety Information Before attempting to operate your unit, read the instructions in this manual thoroughly. Throughout this manual, you will find notations enclosed in double-bordered boxes similar to the one below. DANGER Hot cooking oil causes severe burns. Never attempt to move a fryer containing hot cooking oil or to transfer hot cooking oil from one container to another. CAUTION boxes contain information about actions or conditions that may cause or result in a malfunction of your system. WARNING boxes contain information about actions or conditions that may cause or result in damage to your system, and which may cause your system to malfunction. DANGER boxes contain information about actions or conditions that may cause or result in injury to personnel, and which may cause damage to your system and/or cause your system to malfunction. Fryers in this series are equipped with the following automatic safety features: 1. Two high-temperature detection features shut off power to the elements should the temperature controls fail. 2. A safety switch built into the drain valve prevents the elements from heating with the drain valve even partially open. 1-1 1.3 Controller Information This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. While this device is a verified Class A device, it has been shown to meet the Class B limits. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. The user may find the following booklet prepared by the Federal Communications Commission helpful: "How to Identify and Resolve Radio-TV Interference Problems". This booklet is available from the U.S. Government Printing Office, Washington, DC 20402, Stock No. 004-000-00345-4. 1.4 Shipping Damage Claim Procedure What to do if this equipment arrives damaged: Please note that this equipment was carefully inspected and packed by skilled personnel before leaving the factory. The freight company assumes full responsibility for safe delivery upon acceptance of the equipment. 1. File Claim for Damages Immediately—Regardless of extent of damage. 2. Visible Loss or Damage—Be sure this is noted on the freight bill or express receipt and is signed by the person making the delivery. 3. Concealed Loss or Damage—If damage is unnoticed until equipment is unpacked, notify the freight company or carrier immediately and file a concealed damage claim. This should be done within 15 days of date of delivery. Be sure to retain container for inspection. 1.5 Service Information For non-routine maintenance or repairs, or for service information, contact your local Frymaster Authorized Service Center (FASC). Service information may also be obtained by calling the Frymaster Technical Services Department (1-800-551-8633) or via e-mail at service @frymaster.com. The following information will be needed in order to assist you efficiently: Model Number: Serial Number: Voltage: Also be prepared to describe the specific problem. RETAIN AND STORE THIS MANUAL IN A SAFE PLACE FOR FUTURE USE. 1-2 NAVY SURFACE SHIP ELECTRIC FRYERS CHAPTER 2: INSTALLATION INSTRUCTIONS 2.1 Introduction The instructions in this chapter cover all configurations of Navy Surface Ship Electric Fryer models specifically configured for use aboard surface ships of the U.S. Navy, including H14SC/H17SC/H22SC kW and FPH17SC kW filtration system models. The instructions do not cover and may not be used for installations aboard submarines or ashore. Proper installation is essential for the safe, efficient, trouble-free operation of this appliance. Any unauthorized alteration of this equipment will void the Frymaster warranty. NOTICE All fryers shipped without factory supplied cords and plug assemblies must be hardwired using flexible conduit to the terminal block located on the rear of the fryer. These fryers should be wired to NEC specifications. Hardwired units must include installation of restraint devices. DANGER Adequate means must be provided to limit the movement of this appliance without depending on or transmitting stress to the electrical conduit NOTICE If this equipment is wired directly into the electrical power supply, a means for disconnection from the supply having a contact separation of at least 3-mm in all poles must be incorporated in the fixed wiring. NOTICE This equipment must be positioned so that the plug is accessible unless other means for disconnection from the power supply (e.g., a circuit breaker) is provided. NOTICE If this appliance is permanently connected to fixed wiring, it must be connected by means of copper wires having a temperature rating of not less than 167°F (75°C). NOTICE If the electrical power supply cord is damaged, it must be replaced by a Frymaster Dean Factory Authorized Service Center technician or a similarly qualified person in order to avoid a hazard. DANGER This appliance must be connected to a power supply having the same voltage and phase as specified on the rating plate located on the inside of the appliance door. 2-1 DANGER All wiring connections for this appliance must be made in accordance with the wiring diagram(s) furnished with the appliance. Refer to the wiring diagram(s) affixed to the inside of the appliance door when installing or servicing this equipment. DANGER The appliance area must be kept free and clear of combustible material at all times. WARNING Do not block the area around the base or under the fryers. All installation and service on FRYMASTER equipment must be performed by qualified, certified, licensed, and/or authorized installation or service personnel. Service may be obtained by contacting a local Frymaster DEAN Factory Authorized Service Center. In the event of a power failure, the fryer(s) will automatically shut down. If this occurs, turn the power switch OFF. Do not attempt to start the fryer(s) until power is restored. A clearance of 6 inches (15cm) must be provided at both sides and back adjacent to combustible construction. A minimum of 24 inches (61cm) should be provided at the front of the equipment for servicing and proper operation. Connections should be made by means of an approved, flexible-metallic or rubber-covered electrical cable and quick-disconnect plug. The fryers may be installed with “hard-wired” connections, but use of quick-disconnect plugs will facilitate service if required. Connections are made to the fryer power input terminal block located in lower back of the fryer(s). DANGER Observe the following precautions when connecting the fryer to an emergency cutoff system: ● Be sure that each fryer is connected to a dedicated set of contacts in the emergency cutoff system. ● Do not connect the contacts in series. ● Do not connect more than one fryer to each set of contacts. ● The contacts MUST be normally closed contacts that open in an emergency. ● The contacts CANNOT have an external voltage applied. 2-2 2.2 Power Requirements MODEL H14SC H14SC H17SC/FPH17SC H17SC/FPH17SC H22SC H22SC VOLTAGE 440 480 440 480 440 480 PHASE 3 3 3 3 3 3 WIRE SERVICE 3 3 3 3 3 3 MIN. SIZE 8 8 6 6 6 6 AWG (mm2) (10) (10) (16) (16) (16) (16) L1 19 17 23 21 29 27 AMPS PER LEG L2 19 17 23 21 29 27 L3 19 17 23 21 29 27 The FPH17SC Navy Surface Ship electric fryers are equipped with a filter system that requires a separate 120VAC, single-phase, 3-wire, 20 amp service (refer to wiring diagrams in sections 7.12 and 7.13). NOTICE If this appliance is permanently connected to fixed wiring, it must be connected by means of copper wires having a temperature rating of not less than 167°F (75°C). DANGER This appliance must be connected to a power supply having the same voltage and phase as specified on the rating plate located on the inside of the appliance door. DANGER All wiring connections for this appliance must be made in accordance with the wiring diagram(s) furnished with the appliance. Refer to the wiring diagram(s) affixed to the inside of the appliance door when installing or servicing this equipment. 2.3 Installation 1. This equipment must be securely bolted to the deck. 2. Install deck studs for the specific fryer configuration in accordance with the diagrams at the end of this chapter. 3. Position the fryer on the deck studs and secure with appropriate nuts and lock washers. 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. 2-3 2.4 After Fryers Are Anchored At the Frying Station DANGER Hot oil can cause severe burns. Avoid contact. Under all circumstances, oil must be removed from the fryer before attempting to move it to avoid oil spills, falls and severe burns. This fryer may tip and cause personal injury if not secured in a stationary position. 1. Close frypot drain-valve(s) and fill frypot(s) with water to the bottom oil level line. 2. Boil out frypot(s) in accordance with the instructions in Section 5.1.3 of this manual. 3. Drain, clean, and fill frypot(s) with cooking oil. Procedures in Chapter 3.) 2.5 (See Equipment Setup and Shutdown Dimensions and Weights Single Fryer (with Filter): LWH (inches) 33.80 X 15.58 X 45.5 - 295 lbs. empty. Single Fryer: LWH (inches) 33.38 X 15.67 X 45.5 – 190 lbs. empty. 2-Fryer Battery: LWH (inches) 33.39 X 31.45 X 45.5 – 490 lbs. empty. 3-Fryer Battery: LWH (inches) 33.24 X 47.10 X 45.5 – 570 lbs. empty. 4-Fryer Battery: LWH (inches) 33.45 X 62.55 X 45.5 – 780 lbs. empty. 20.98 5.35 2.70 Back of Fryer Unit 14.51 Front Handle 16.51 24.36 24.36 2.00 Mounting Holes Ø .625, 4 Places 33.80 Single Fryer (with Filter) 2-4 10.18 15.58 33.38 28.29 17.534 20.48 Front Handle 15.67 20.48 Back of Fryer Unit 2.465 10.580 Mounting Holes Ø .625, 4 Places Single Fryer (non-filter) 26.316 2.470 7.098 Typical Back of Fryer Unit 31.62 31.62 33.39 17.515 Mounting Holes Ø .625, 4 Places Front Handle 31.45 2-Fryer Battery 2-5 14.400 27.570 Back of Fryer Unit 7.229 32.66 32.66 22.66 22.66 17.516 33.24 Mounting Holes Ø .625, 4 Places Front Handle 47.1 3-Fryer Battery 62.55 2.470 26.320 31.180 Back of Fryer Unit 7.119 7.119 31.61 31.61 35.76 35.76 17.490 Mounting Holes Ø .625, 4 Places Front Handle 4-Fryer Battery 2-6 33.45 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 elements. Failure to do so will result in irreparable damage to the elements and may cause a fire. DANGER Remove all drops of water from the frypot before filling with cooking oil. Failure to do so will cause spattering of hot liquid when the oil is heated to cooking temperature. 1. Fill the frypot with cooking oil to the bottom OIL LEVEL line located on the rear of the frypot. This will allow for oil expansion as heat is applied. Do not fill cold oil any higher than the bottom line; overflow may occur as heat expands the oil. NOTE: If solid shortening is used, first raise the elements, then pack the shortening into the bottom of the frypot. Lower the elements, and then pack the shortening around and over the elements. It may be necessary to add shortening to bring the level up to the proper mark after the packed shortening has melted. DANGER Never set a complete block of solid shortening on top of the heating elements. When using solid shortening, always pre-melt the shortening before adding it to the frypot. If the shortening is not pre-melted, it must be packed down into the bottom of the frypot and between the elements, and the fryer must be started in the melt-cycle mode. Never cancel the melt-cycle mode when using solid shortening. Doing so will result in damage to the elements and increase the potential for a flash fire. 2. If the fryer(s) is/are not hard-wired into the power supply, ensure that the power cord(s) is/are plugged into the appropriate receptacle(s). Verify that the face of the plug(s) is/are flush with the outlet plate, with no portion of the prongs visible. 3. Ensure that the oil level is at the top OIL LEVEL line when the oil is at its cooking temperature. It may be necessary to add oil to bring the level up to the proper mark, after it has reached cooking temperature. 3–1 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 Solid-State Analog Controller NOTE: Refer to Chapter 4 of this manual for operating instructions for the built-in filtration system. Fryers configured for the U.S. Navy are equipped with solid-state analog controllers. 2 1 3 5 4 6 7 U.S. Navy Solid-State Analog Controller ITEM DESCRIPTION 1 Power Switch – Controls electrical power to fryer. 2 Power-On Light – Indicates when electrical power to fryer is ON. 3 Heating Mode Light – Indicates when heating element is ON. 4 Trouble Light – Indicates over high-limit or problem in heat control circuitry. 5 Thermostat Control Knob – Sets desired frying temperature. 6 Hi-Limit Test Switch – Tests high-limit thermostat. 7 Second Hi-Limit Test Light – Indicates fryer is in second high-limit test mode. The analog controller, illustrated above, is used to adjust and maintain oil at the temperature indicated by the thermostat knob. The fryer has two built-in high-limit protection features. If the temperature in the frypot reaches approximately 410°F, the controller opens the heat relay circuit, turning the elements off. If the temperature in the frypot reaches 450°F, a mechanical high-limit shuts off electrical power to the elements. The operator should periodically test each of the high-limit protection features, using the procedure at the end of this chapter, to verify that they are operating correctly. 3–2 The analog controller has no timing features. The operator must monitor shake and pull times. WARNING Before pressing the power switch to the ON position, ensure that the frypot is properly filled with oil. See Section 3.1. CONTROLLER OPERATING PROCEDURE 1. Verify that the thermostat knob is set to the desired cooking temperature. 2. Press the power switch to the ON position. The POWER light will illuminate. 3. If the frypot temperature is below 180°F, the controller will automatically enter a warm-up cycle (often called a melt cycle). The heating elements will cycle on and off repeatedly, allowing the oil to heat gradually, without scorching. During the warm-up cycle, the heating mode light will alternately illuminate and go off as the elements cycle on and off. Within about 45 minutes, the controller will exit the warm-up cycle and the heating mode light will remain continuously illuminated. 4. When the oil temperature reaches the thermostat knob setpoint, the elements will cycle OFF and the HEAT light will go off, indicating that the fryer is ready for the cooking process to begin. HIGH-LIMIT TEST PROCEDURE Tools Required: One 0-600°F pyrometer with sensing probe or an equivalent high-temperature thermometer. NOTE: Conduct this test when the fryer will not be needed for about one hour and when the cooking oil is due to be changed (the test will ruin the cooking oil). Start the test with the controller turned ON and with the cooking oil at normal frying temperature. Stir the oil thoroughly to ensure even distribution and temperature. DANGER If the expected results (indicated by italics) for Steps 3 and 4 below do not occur, turn off the fryer at the main circuit breaker panel and do not use the fryer until it has been repaired by an authorized technician. 1. Verify that cooking oil is at the bottom OIL-LEVEL line. Add oil if necessary. 2. Turn the power switch ON and set the control knob to the normal frying temperature. 3. Insert the pyrometer probe into the frypot so that its tip is near the temperature probe on the element (i.e., approximately 5-inches into the oil, near the center of the frypot). Press and hold the high-limit test switch in the “1st” test position until the TROUBLE light illuminates. Release the test switch. The trouble light should have come on when the temperature was approximately 410°F (± 10°F) and the heating elements should have de-energized (indicated by the HEAT light going out). 3–3 4. Press and hold the high-limit test switch in the “2nd” test position until the 2nd High-Limit light illuminates. Release the switch. The 2nd High-Limit light should have come on when the temperature was between 430°F and 460°F. For fryers connected to an external shunt power supply, all fryers should have been shut off completely and all control panel lights should have been extinguished. For fryers not connected to an external shunt power supply, only the fryer being tested should have been shut off. 5. Place the controller power switch in the OFF position. 6. Allow the cooking oil to cool to below normal frying temperature. When the power switch is again placed in the ON position, the elements should re-energize and the operating thermostat should resume control of the temperature. If the TROUBLE light remains on instead, allow the oil additional time to cool. 3–4 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 remain in operation. Section 4.2 covers preparation of the filter system for use. Operation of the system is covered in section 4.3. WARNING The work center supervisor is responsible for ensuring that operators are made aware of the inherent hazards of operating a hot oil filtering system, particularly the aspects of oil filtration, draining and cleaning procedures. 4.2 Preparing the Filter for Use 1. Rotate the pan-locking rod to either side until it clears the filter pan, then pull the pan out from the cabinet. Remove the crumb tray, hold-down ring and filter screen. Clean all components with a solution of detergent and hot water then dry thoroughly. Rotate the locking rod to either side to allow the pan to be pulled out from the fryer. The filter pan is equipped with rollers in rails, much like a kitchen drawer. The pan may be removed for cleaning or to gain access to interior components by lifting the front of the pan to disengage the front rollers, then pulling it forward until the rear rollers clear the rails. The pan cover must not be removed except for cleaning, interior access, or to allow a shortening disposal unit (SDU) to be positioned under the drain. Inspect O-Rings 2. Inspect the filter pan connection fitting to ensure that both O-rings are in good condition. O-rings are located on the tube disconnect inside the filter pan as shown to the right. 4-1 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, overlapping on all sides. Screen Filter Paper 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 bottom of the pan. 5. When the hold-down ring is in position, sprinkle one packet of filter powder evenly over the paper. 6. Replace the crumb tray in the filter pan, then push the filter pan back into the fryer, positioning it under the drain. 4.3 Operation of the Filter DANGER Draining and filtering of cooking oil must be accomplished with care to avoid the possibility of a serious burn caused by careless handling. The oil to be filtered is at or near 350°F. Ensure drain handles are in their proper position before operating any switches or valves. Wear all appropriate safety equipment when draining and filtering cooking oil or shortening. DANGER NEVER attempt to drain cooking oil from the fryer with the elements energized! Doing so will cause irreparable damage to the elements and may cause a flash fire. Doing so will also void the Frymaster warranty. 1. Ensure that the filter is prepared. See Sec. 4.2. 2. Make sure the oil is at operating temperature. 3. Turn the fryer power OFF. Drain the frypot into the filter pan by rotating the valves 90º. If necessary, use the Fryer's Friend clean-out rod to clear the drain from inside the frypot. Open drain valve by rotating 90º. 4-2 DANGER Do not drain more than one frypot at a time into the built-in filtration unit to avoid overflow and spillage of hot oil. DANGER NEVER attempt to clear a clogged drain valve from the front of the valve! Hot oil will rush out creating the potential for severe burns. DO NOT hammer on the drain valve with the cleanout rod or other objects. Damage to the ball inside will result in leaks and will void the Frymaster warranty. 4. After the cooking oil has drained from the frypot, turn the filter handle to the ON position to start the pump and begin the filtering process. There may be a slight delay before the pump activates. Turn filter handle to the ON position. 5. The filter pump draws the cooking oil through the filter medium and circulates it back up to and through the frypot during a 5-minute process called polishing. Polishing cleans the oil by trapping solid particles in the filter medium. 6. After the oil is filtered (about 5 minutes), close the drain valve and allow the fryer to refill. Let the filter pump run 10 to 12 seconds after the oil begins to bubble. Turn the filter off. WARNING The filter pump is equipped with a manual reset switch (see photo below) in case the filter motor overheats or an electrical fault occurs. If this switch trips, turn off power to the filter system and allow the pump motor to cool 20 minutes before attempting to reset the switch. Filter Pump Reset Switch 7. Lower the elements into the frypot and reinstall the basket support rack. Ensure the drain valve is fully closed. (If the drain valve is not fully closed, the fryer will not operate.) Turn the fryer ON and allow the cooking oil to reach setpoint. 4-3 DANGER The crumb tray must be emptied into a fireproof container at the end of frying operations each day. Some food particles can spontaneously combust if left soaking in certain shortening. WARNING Do not bang fry baskets or other utensils on the fryer’s joiner strip. The strip is present to seal the joint between the fry vessels. Banging fry baskets on the strip to dislodge shortening will distort the strip, adversely affecting its fit. It is designed for a tight fit and should only be removed for cleaning. 4.4 Draining and Disposing of Waste Oil When your cooking oil has reached the end of its usable life, drain the oil into an appropriate METAL container for transport to the disposal container. Frymaster recommends the use of the Frymaster Shortening Disposal Unit (SDU). NOTE: If using an SDU built before January 2004 the filter pan cover must be removed to allow the unit to be positioned beneath the drain. To remove the lid, lift up on the front edge and pull it straight out of the cabinet. Refer to the documentation furnished with the disposal unit for specific operating instructions. If a shortening disposal unit is not available, allow the oil to cool to 100°F, then drain the oil into a metal stockpot or similar metal container. When draining is finished, close the fryer drain valve securely. DANGER Allow oil to cool to 100°F before draining into an appropriate container for disposal. When draining oil into a disposal unit, do not fill above the maximum fill line located on the container. 4-4 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 soaking in certain shortening material. DANGER Never attempt to clean the fryer during the frying process or when the frypot is filled with hot oil. If water comes in contact with oil heated to frying temperature, it will cause spattering of the oil, which can result in severe burns to nearby personnel. WARNING Use a commercial-grade cleaner formulated to effectively clean and sanitize food-contact surfaces. Read the directions for use and precautionary statements before use. Particular attention must be paid to the concentration of cleaner and the length of time the cleaner remains on the food-contact surfaces. 5.1.1 Clean Inside and Outside of the Fryer Cabinet – Daily Clean inside the fryer cabinet with a dry, clean cloth. Wipe all accessible metal surfaces and components to remove accumulated oil/shortening and dust. Clean outside the fryer cabinet, with a clean, damp cloth soaked with dishwashing detergent. Wipe with a clean, damp cloth. 5.1.2 Clean the Built-in Filtration System – Daily WARNING Never drain water into the filter pan. Water will damage the filter pump. There are no periodic preventive maintenance checks and services required for the FootPrint Pro Filtration System other than daily cleaning of the filter pan and associated components with a solution of hot water and detergent. 5–1 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 elements. Failure to do so will result in irreparable damage to the elements and may cause a fire. Boiling Out the Frypot Before the fryer is first used, it should be boiled out to ensure that residue from the manufacturing process has been eliminated. Also, after the fryer has been in use for a period of time, a hard film of caramelized vegetable oil will form on the inside of the frypot. This film should be periodically removed by following the boil-out procedure that follows. 1. Before switching the fryer(s) ON, close the frypot drain valve(s), then fill the empty frypot with a mixture of cold water and dishwashing detergent. Follow instructions on detergent container when mixing. 2. Press the fryer ON/OFF switch to the ON position. 3. Set the temperature control knob to the lowest setting. 4. Simmer the solution for 45 minutes to one hour. Do not allow the water level to drop below the bottom oil-level line in the frypot during the boil-out operation. DANGER Never leave the fryer unattended during the boil-out process. If the boil-out solution boils over, turn the fryer off immediately and let the solution cool for a few minutes before resuming the process. 5. Turn the fryer ON/OFF switch(s) to the OFF position. 6. Add two gallons of water. Drain out the solution and clean the frypot(s) thoroughly. WARNING Do not drain boil-out solution into a shortening disposal unit, a built-in filtration unit, or a portable filter unit. These units are not intended for this purpose, and will be damaged by the solution. 7. Refill the frypot(s) with clean water. Rinse the frypot(s) twice, drain and dry with a clean towel. Thoroughly remove all water from the frypot and elements before refilling the frypot with cooking oil. DANGER Remove all drops of water from the frypot before filling with cooking oil. Failure to do so will cause spattering of hot liquid when the oil is heated to cooking temperature. 5–2 5.1.4 Clean Detachable Parts and Accessories – Weekly Wipe all detachable parts and accessories with a clean, dry cloth. Use a clean cloth saturated with detergent to remove accumulated carbonized oil on detachable parts and accessories. Rinse the parts and accessories thoroughly with clean water and wipe dry before reinstalling. 5.2 Check Calibration of Temperature Control Knob – Monthly 1. After the cooking oil reaches operating temperature, let the heating elements cycle at least four times (indicated by the HEAT light going out and coming back on). 2. Insert a thermometer or pyrometer probe near the temperature-sensing probe approximately five inches deep into the cooking oil. When the heating elements cycle on for the fourth time, the thermometer should read within ±5°F of the temperature control knob setting. 3. If the knob requires adjustment: a. Loosen the setscrew in the control knob until the outer shell of the knob will rotate on the insert inside the knob. b. Rotate the outer shell of the knob until the index line on the knob aligns with the mark that corresponds to the thermometer or pyrometer reading. c. Hold the knob and tighten the setscrew. d. Recheck the thermometer or pyrometer reading and the temperature control knob setting the next time the HEAT light illuminates. e. Repeat steps a through d until the thermometer or pyrometer reading and the knob setting agree within 5°F. 5-3 5.3 Annual/Periodic System Inspection This appliance should be inspected and adjusted periodically by qualified service personnel as part of the galley material maintenance management (3M) program. Frymaster recommends that a Factory Authorized Service Technician inspect this appliance at least annually as follows: Fryer • Inspect the cabinet inside and out, front and rear for excessive oil. • Verify that the heating element wires are in good condition and that leads have no visible fraying or insulation damage and that they are free of oil. • Verify that heating elements are in good condition with no carbon/caramelized oil build-up. Inspect the elements for signs of extensive dry-firing. • Verify that the tilt mechanism is working properly when lifting and lowering elements, and that the element wires are not binding and/or chafing. • Verify the heating-element amp-draw is within the allowed range as indicated on the appliance’s rating plate. • Verify that the temperature and high-limit probes are properly connected, tightened and functioning properly, and that mounting hardware and probe guards are present and properly installed. • Verify that component box and contactor box components (i.e. controller, relays, interface boards, transformers, contactors, etc.) are in good condition and free from oil and other debris. • Verify that component box and contactor box wiring connections are tight and that wiring is in good condition. • Verify that all safety features (i.e. contactor shields, drain safety switches, reset switches, etc.) are present and functioning properly. • Verify that the frypot is in good condition and free of leaks and that the frypot insulation is in serviceable condition. • Verify that all wiring harnesses and wiring connections are tight and in good condition. Built-In Filtration System • Inspect all oil-return and drain lines for leaks and verify that all connections are tight. • Inspect the filter pan for leaks and cleanliness. If there is a large accumulation of crumbs in the crumb basket, instruct the work center supervisor/watch supervisor that the crumb basket must be emptied into a fireproof container and cleaned daily. 5–4 • Verify that all O-rings and seals (including those on the quick-disconnect 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. • With the filter pan empty, place each oil return handle, one at a time, in the ON position. Verify that the pump activates and that bubbles appear in the oil of the associated frypot. • Close all oil return valves (i.e., place all oil return handles in the OFF position). Verify proper functioning of each oil return valve by activating the filter pump using the lever on one of the oil return handle microswitches. No air bubbles should be visible in any frypot. • Verify that the filter pan is properly prepared for filtering, then drain a frypot of oil heated to 350°F into the filter pan and close the frypot drain valve. Place the oil return handle in the ON position. Allow all oil to return to the frypot indicated by bubbles in the cooking oil. Return the oil return handle to the OFF position. The frypot should have refilled in no more than 2 minutes and 30 seconds. 5-5 NAVY SURFACE SHIP ELECTRIC FRYERS CHAPTER 6: OPERATOR TROUBLESHOOTING 6.1 Introduction This section provides an easy reference guide to some of the common problems that may occur during the operation of this equipment. The troubleshooting guides that follow are intended to help correct, or at least accurately diagnose, problems with this equipment. Although the chapter covers the most common problems reported, you may encounter problems that are not covered. In such instances, the Frymaster Technical Services staff will make every effort to help you identify and resolve the problem. When troubleshooting a problem, always use a process of elimination starting with the simplest solution and working through to the most complex. Never overlook the obvious – anyone can forget to plug in a cord or fail to close a valve completely. Most importantly, always try to establish a clear idea of why a problem has occurred. Part of any corrective action involves taking steps to ensure that it doesn’t happen again. If a controller malfunctions because of a poor connection, check all other connections, too. If a fuse continues to blow, find out why. Always keep in mind that failure of a small component may often be indicative of potential failure or incorrect functioning of a more important component or system. Before calling a service agent or the Frymaster HOTLINE (1-800-551-8633) or contacting via e-mail at service@frymaster.com: • Verify that power is connected and that circuit breakers are on. • Verify that frypot drain valves are fully closed. DANGER Hot cooking oil will cause severe burns. Never attempt to move this appliance when filled with hot cooking oil or to transfer hot cooking oil from one container to another. DANGER This equipment should be disconnected from the electrical power supply when servicing, except when electrical circuit tests are required. Use extreme care when performing such tests. This appliance may have more than one electrical power supply connection point. Disconnect all power supplies before servicing. Inspection, testing, and repair of electrical components should be performed by authorized personnel only. 6-1 6.2 Troubleshooting 6.2.1 Control and Heating Problems Problem Probable Causes A. Power cord is not plugged in or circuit breaker is tripped. B. Controller has failed. Controller won't activate. C. Power supply component or interface board has failed. A. Drain valve is open. B. Controller has failed. Fryer does not heat. C. One or more other components have failed. 6-2 Corrective Action A. Plug power cord in and verify that circuit breaker is not tripped. B. If available, substitute a controller known to be working for the suspect controller. If the substitute controller functions correctly, order a new controller. C. If any of the components in the power supply system (including the transformer and interface board) fail, power will not be supplied to the controller and it will not function. Determining which component has failed is beyond the scope of operator troubleshooting. Call FASC. A. This fryer is equipped with a drain safety switch that prevents the heating element from being energized if the drain valve is not fully closed. Verify that the drain valve is fully closed. B. If available, substitute a controller known to be working for the suspect controller. If the substitute controller functions correctly, order a new controller. C. If the circuitry in the fryer control system cannot determine the frypot temperature, the system will not allow the element to be energized or will de-energize the element if it is already energized. If the contactor, element, or associated wiring fails, the element will not energize. Determining which specific component is malfunctioning is beyond the scope of operator troubleshooting. Call FASC. Problem Fryer repeatedly cycles on and off when first started. Probable Causes Fryer is in melt-cycle mode. Fryer does not heat after filtering. Drain valve is open. Fryer heats until high limit trips with heat indicator ON. Temperature probe or controller has failed. Fryer heats until high limit trips without heat indicator ON. Fryer stops heating with heat indicator ON. Contactor or controller has failed. The high limit thermostat or contactor has failed. 6-3 Corrective Action 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). The purpose of the melt-cycle is to allow controlled melting of solid shortening to prevent scorching and flash fires or damage to the element. This fryer is equipped with a drain safety switch that prevents the heating element from being energized if the drain valve is not fully closed. Verify that the drain valve is fully closed. If available, substitute a controller known to be working for the suspect controller. If the substitute controller functions correctly, order a new controller. If substitution of the controller does not resolve the problem, the most likely cause is a failed temperature probe. If available, substitute a controller known to be working for the suspect controller. If the substitute controller functions correctly, order a new controller. If substitution of the controller does not resolve the problem, the most likely cause is a contactor failed in the closed position. The fact that the heat indicator is ON indicates that the controller is functioning properly and is calling for heat. The high limit thermostat functions as a normally closed switch. If the thermostat fails, the "switch" opens and power to the elements is shut off. If the contactor fails to close, no power is supplied to the elements. Determining which component has failed is beyond the scope of operator troubleshooting. Call FASC. 6.2.2 Error Messages and Display Problems Problem Probable Causes Controller trouble light ON. Oil temperature above acceptable range or a problem with the temperature measuring circuitry. Controller trouble light ON and heating mode light ON. Open drain valve or problem with latching circuits Corrective Action This in an indication of a malfunction in the temperature measuring or control circuitry, including a failure of the high limit thermostat. Determining the specific problem is beyond the scope of operator troubleshooting. Shut the fryer down immediately. Verify that the drain valve is fully closed. The fryer will not function if the drain valve is not fully closed. If the drain valve is fully closed, the problem is within the latching circuitry and is beyond the scope of operator troubleshooting. 6.2.3 Filtration Problems Problem Probable Causes A. Verify that the power cord is fully plugged in. If so, verify that circuit breaker is not tripped. B. If the motor is too hot to touch for more than a few seconds, the B. Pump motor has overheated thermal overload switch has causing the thermal overload probably tripped. Allow the switch to trip. motor to cool at least 20 minutes then press the Pump Reset Switch. C. Blockage in filter pump. C. Pump blockages are usually caused by sediment buildup in Test: Close the drain valve and the pump due to improperly pull the filter pan out from the sized or installed filter paper fryer. Activate the pump. If the and failure to use the crumb pump motor hums for a short time screen. then stops, the probable cause is blockage of the pump itself. A. Power cord is not plugged in or circuit breaker is tripped. Filter pump won't start. Corrective Action (continued on following page) 6-4 Problem Probable Causes Blockage in filter pan suction tube. Filter pump runs but oil does not return to frypot and there is no bubbling oil. Test: Close the drain valve and pull the filter pan out from the fryer. Activate the pump. If bubbling oil occurs, there is a blockage in the filter pan suction tube. A. Improperly installed filter pan components. Filter pump runs, but oil return is very slow and bubbling oil occurs. Corrective Action The blockage may be caused by sediment buildup or, if solid shortening is used, solidified shortening in the tube. Use a thin, flexible wire to remove the blockage. If the blockage cannot be removed, call FASC. A. Verify that filter screen is in bottom of pan with paper top of screen. Verify that O-rings are present and in good condition on filter pan connection fitting. B. In order to properly filter, the oil or shortening should be at or near 350ºF (177ºC). At temperatures lower than this, the oil becomes too thick to B. Attempting to filter with oil or pass through the filter medium shortening that is not hot enough. easily, resulting in much slower oil return and eventual overheating of the filter pump motor. Make sure oil is at or near frying temperature before draining oil into filter pan. 6-5 NAVY SURFACE SHIP ELECTRIC FRYERS CHAPTER 7: SERVICE PROCEDURES 7.1 General Before performing any maintenance on this equipment, disconnect the fryer from the electrical power supply. When electrical wires are disconnected, it is recommended that they be marked in such a way as to facilitate re-assembly. 7.2 Replacing a Controller 1. Disconnect the fryers from the electrical power supply. 2. The controller bezel is held in place by tabs at the top and bottom. Slide the bezel up to disengage the lower tabs. Then slide the bezel down to disengage the upper tabs. If applicable, remove the top two screws holding the controller to the control panel frame. The control panel is hinged at the bottom and will swing open from the top. 3. Unplug the wiring harness from the connector on the back of the controller and disconnect the grounding wire from terminal adjacent to the connector. Remove the control panel assembly by lifting it from the hinged slots in the control panel frame. 15-Pin Connector Ground Wire Terminal 4. Remove the controller from the control panel assembly and install the replacement controller. Reinstall the control panel assembly by reversing steps 1 and 2. 7.3 Replacing Component Box Components 1. Remove the control panel (see steps 1 - 3 of section 7.2 on the preceding page). 2. Unplug the wiring harness from the 15-pin connector on the interface board and disconnect the grounding wire from terminal adjacent to the 15-pin connector on the back of the controller. Remove the control panel assembly by lifting it from the hinge slots in the control panel frame. 3. Disconnect the wiring from the component to be replaced, being sure to make a note of where each wire was connected. 7-1 4. Dismount the component to be replaced and install the new component, being sure that any required spacers, insulation, washers, etc. are in place. NOTE: If more room to work is required, the control panel frame assembly may be removed by removing the hex head screws that secure it to the fryer cabinet (see illustration below). If this option is chosen, all front panel assemblies must be removed per steps 2-4 above. The cover plate on the lower front of the component box may also be removed if desired. Removing the component box itself from the fryer is not recommended due to the difficulty involved in disconnecting and reconnecting the oil-return valve rods, which pass through openings in the component box. Remove these three screws at each end. Remove these two screws from the center supports. Removing the Control Panel Frame and Top Cap Assembly 5. Reconnect the wiring disconnected in Steps 2 and 3, referring to your notes and the wiring diagrams on the fryer door to ensure that the connections are properly made. Also, verify that no other wiring was disconnected accidentally during the replacement process. 6. Reverse steps 1-4 to complete the replacement and return the fryer to service. 7.4 Replacing a High-Limit Thermostat 1. Remove the filter pan and lid from the unit. Drain the frypots into a Shortening Disposal Unit (SDU) or other appropriate metal container. DANGER DO NOT drain more than one full frypot or two split frypots into the SDU at one time. 2. Disconnect the fryer from the electrical power supply and reposition it to gain access to the rear of the fryer. 7-2 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. Unplug the 12-pin connector C-6 and using a pin-pusher push the pins of the high-limit out of the connector. 5. Using a wrench, carefully unscrew the high-limit thermostat to be replaced. 6. Apply Loctite™ PST 567 or equivalent sealant to the threads of the replacement and screw it securely into the frypot. 7. Insert the leads into the 12-pin connector C-6 (see illustration below). For full-vat units or the left half of a dual-vat unit (as viewed from the rear of the fryer) the leads go into positions 1 and 2 of the connector. For the right half of a dual-vat unit (as viewed from the rear of the fryer), the leads go into positions 7 and 8. In either case, polarity does not matter. 8. Reconnect the 12-pin connecting plug C-6. Use wire ties to secure any loose wires. 9. Reinstall the back panels reposition the fryer under the exhaust hood, and reconnect it to the electrical power supply to return the fryer to service. 7.5 Replacing a Temperature Probe 1. Remove the filter pan and lid from the unit. Drain the frypots into a Shortening Disposal Unit (SDU) or other appropriate metal container. DANGER DO NOT drain more than one full frypot or two split frypots into the SDU at one time. 2. Disconnect the fryer from the electrical power supply and reposition it to gain access to the rear of the fryer. 3. Remove the four screws from both sides of the lower back panel. Then remove the two screws on both the left and right sides of the back of the tilt housing. Lift the tilt housing straight up to remove from the fryer. 4. Locate the red and white wires of the temperature probe to be replaced. Note where the leads are connected prior to removing them from the connector. Unplug the 12-pin connector C-6 and using a pin-pusher push the pins of the temperature probe out of the connector. 5. Raise the element and remove the securing probe bracket and metal tie wraps that secure the probe to the element (see illustration on the following page). 7-3 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. Secure the probe to the elements using the bracket which was removed in Step 5 and the metal tie wraps which were included in the replacement kit. 8. Route the probe wires out of the tube assembly following the element wires down the back of the fryer through the Heyco bushings to the 12-pin connector C-6. Secure the wires to the sheathing with wire ties. 9. Insert the temperature probe leads into the 12-pin connector C-6 (see illustration below). For full-vat units or the right half of a dual-vat unit (as viewed from the rear of the fryer) the red lead goes into position 3 and the white lead into position 4 of the connector. For the left half of a dual-vat unit (as viewed from the rear of the fryer), the red lead goes into position 9 and the white lead into position 10. NOTE: Right and left refer to the fryer as viewed from the rear. 10. Secure any loose wires with wire ties making sure that the lead wires will not interfere with the movement of the springs. Rotate the elements up and down making sure that movement is not restricted and that the wires are not pinched. 11. Reinstall the tilt housing and back panels, reposition the fryer under the exhaust hood, and reconnect it to the electrical power supply to return the fryer to service. 7.6 Replacing a Heating Element 1. Perform steps 1-3 of section 7.5, Replacing a Temperature Probe. 7-4 2. On dual-vat fryers, and on full-vat fryers where the temperature probe is attached to the element being replaced, disconnect the wire harness containing the probe wiring. Using a pin pusher, disconnect the probe wires from the 12-pin connector C-6. 3. In the rear of the fryer directly behind the frypot disconnect the 6-pin connector for the left element (as viewed from the front of the fryer) or the 9-pin connector for the right element. Press in on the tabs on each side of the connector while pulling outward on the free end to extend the connector and release the element leads (see photo below). Pull the leads out of the connector and out of the wire sleeving. Note: Liquid resistant seals. 4. Raise the element to the full up position and support the elements. 5. Remove the hex head screws and nuts that secure the element to the tube assembly and pull the element out of the frypot. NOTE: Full-vat elements consist of two dual-vat elements clamped together. For full-vat units, remove the element clamps before removing the nuts and screws that secure the element to the tube assembly. 6. If applicable, recover the probe bracket and probe from the element being replaced and install them on the replacement element, then install the replacement element in the frypot, securing it with the nuts and screws removed in Step 5 to the tube assembly ensuring the gasket is between the tube and element assembly. 7. Route the element leads through the element tube assembly and into the wire sleeving to prevent chafing. Ensure that the wire sleeving is routed back through the Heyco bushing keeping it clear from the lift springs. Also ensure that the wire sleeving extends into the tube assembly to protect the edge of the tube assembly from chafing the wires. Press the pins into the connector in accordance with the diagram below, and then close the connector to lock the leads in place. NOTE: It is critical that the wires be routed through the sleeving to prevent chafing. Index Marker marks Position 1 6L 3 2 1 3 2 1 6 5 4 6 5 4 9 8 7 5L 4L 6 R 3L 2L 1L 7-5 5 4R R 3R 2 1R R 8. Reconnect the element connector it was removed from directly behind the frypot, ensuring that the latches lock. 9. Insert the temperature probe leads into the 12-pin wiring harness connector C-6 (see illustration below). For full-vat units or the right half of a dual-vat unit, the red lead goes into position 3 and the white into position 4. For the left half of a dual-vat unit, the red lead goes into position 9 and the white into position 10. NOTE: Right and left refer to the fryer as viewed from the rear. 10. Reconnect the 12-pin connector C-6 of the wiring harness disconnected in Step 2. 11. Lower the element down onto the basket rack. 12. Reinstall the tilt housing and back panels, reposition the fryer under the exhaust hood, and reconnect it to the electrical power supply. 7.7 Replacing Contactor Box Components 1. If replacing a contactor box component above the built-in filter system, remove the filter pan and lid from the unit. Drain the frypots into a Shortening Disposal Unit (SDU) or other appropriate metal container. If replacing a contactor box component in a non-filter unit or a frypot that’s not over the filter pan, drain the frypot above the box into a Shortening Disposal Unit (SDU) or other appropriate metal container. DANGER DO NOT drain more than one full frypot or two split frypots into the SDU at one time. 2. Disconnect the fryer from the electrical power supply. 3. Remove the two screws securing the cover of the contactor box. The contactor boxes above the filter pan are accessed by sliding under the fryer. They are located to the left and right above the guide rails (see photo below). The contactor boxes of non-filter units or frypots not over the filter pan are accessed by opening the fryer door directly under the affected frypot. Remove two screws to access contactor box components above the filter pan. 7-6 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 steps 1-4 to return the fryer to operation. Left and right views of mechanical contactor box components. 7.8 Replacing a Frypot 1. Drain the frypot into the filter pan or, if replacing a frypot over the filter system, into a Shortening Disposal Unit (SDU) or other appropriate metal container. If replacing a frypot over the filter system, remove the filter pan and lid from the unit. DANGER DO NOT drain more than one full frypot or two split frypots into the SDU at one time. 2. Disconnect the fryer from the electrical power supply and reposition it to gain access to both the front and rear. 3. Slide the metal bezel up to release the bottom tabs, then slide the bezel down to disengage the upper tabs. 4. Remove the two screws from the upper corners of the control panels and allow them to swing down (see illustration and photo on page 7-1). 5. Unplug the wiring harnesses and ground wires from the backs of the controllers. Remove the controllers by lifting them from the hinge slots in the control panel frame. 6. Remove the tilt housing and back panels from the fryer. The tilt housing must be removed first in order to remove the upper back panel. 7. To remove the tilt housing remove the hex head screws from the rear edge of the housing. The housing can be lifted straight up and off the fryer. 8. Remove the control panel by removing the screw in the center and the nuts on both sides. 9. Loosen the component boxes by removing the screws, which secure them in the cabinet. 10. Dismount the top cap by removing the nuts at each end that secure it to the cabinetry. 11. Remove the hex head screw that secures the front of the frypot to the cabinet cross brace. 7-7 12. Remove the top-connecting strip that covers the joint with the adjacent frypot. 13. Unscrew the Teflon vent/vacuum-breaker tube fitting, unscrew the nut located on the front of each section of drain tube, and remove the tube assembly from the fryer. 14. Remove the covers from the drain safety switch(es) and disconnect the switch wiring at the switch(es). 15. At the rear of the fryer, unplug the 12-pin connector C-6 and, using a pin pusher, disconnect the high-limit thermostat leads. 16. Disconnect the oil return flexline(s) at the frypot end(s). 17. Raise the elements to the “up” position and disconnect the element springs. 18. Remove the machine screws and nuts that secure the element tube assembly to the frypot. Carefully lift the element assembly from the frypot and secure it to the cross brace on the rear of the fryer with wire ties or tape. 19. Carefully lift the frypot from the fryer and place it upside down on a stable work surface. 20. Recover the drain valve(s), oil return flexline connection fitting(s), and high-limit thermostat(s) from the frypot. Clean the threads and apply Loctite™ PST 567 or equivalent sealant to the threads of the recovered parts and install them in the replacement frypot. 21. Carefully lower the replacement frypot into the fryer. Reinstall the hex head screw removed in step 7 to attach the frypot to the fryer. 22. Position the element tube assembly in the frypot and reinstall the machine screws and nuts removed in step 18. 23. Reconnect the oil return flexlines to the frypot, and replace aluminum tape, if necessary, to secure heater strips to the flexlines. 24. Insert the high-limit thermostat leads disconnected in step 15 (see illustration on page 7-3 for pin positions). 25. Reconnect the drain safety switch wiring to the switch(es) in accordance with the diagram below then reinstall the switch covers. 26. Reinstall the drain tube assembly. 7-8 27. Reinstall the top connecting strips, top cap, tilt housing and back panels. 28. Reinstall controllers in the control panel frame and reconnect the wiring harnesses and ground wires. 29. Reposition the fryer under the exhaust hood and reconnect it to the electrical power supply. 7.9 Built-in Filtration System Service Procedures 7.9.1 Filtration System Problem Resolution One of the most common causes of filtration problems is placing the filter paper on the bottom of the filter pan rather than over the filter screen. CAUTION Ensure that filter screen is in place prior to filter paper placement and filter pump operation. Improper screen placement is the primary cause of filtration system malfunction. Whenever the complaint is “the pump is running, but no oil is being filtered,” check the installation of the filter paper, and ensure that the correct size is being used. While you are checking the filter paper, verify that the O-ring on the bottom of the filter pan is present and in good condition. A missing or worn O-ring allows the pump to take in air and decreases its efficiency. Also, oil leaks on the floor each time a vat is drained. If the pump motor overheats, the thermal overload will trip and the motor will not start until it is reset. If the pump motor does not start, press the red reset switch (button) located on the rear of the motor. If the pump starts after resetting the thermal overload switch, then something is causing the motor to overheat. A major cause of overheating is when several frypots are filtered sequentially, overheating the pump and motor. Allow the pump motor to cool at least 30 minutes before resuming operation. Pump overheating can be caused by: • Solidified shortening in the pan or filter lines, or • Attempting to filter unheated oil or shortening (cold oil and shortening are more viscous, overloading the pump motor and causing it to overheat). Sediment Particle Oil Flow Sediment Particle If the motor runs but the pump does not, there is a blockage in the pump. Incorrectly sized or installed paper/pads will allow food Up for reverse Down for forward 7-9 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 overload, again tripping the thermal overload. Shortening that has solidified in the pump will also cause it to seize, with the same result. A pump seized by debris or hard shortening can usually be freed by manually moving the gears with a screwdriver or other instrument. Disconnect power to the filter system, remove the input plumbing from the pump, and use a screwdriver to manually turn the gears. ● Turning the pump gears in reverse will release a hard particle. ● Turning the pump gears forward will push softer objects and solid shortening through the pump and allow free movement of the gears. Incorrectly sized or installed paper/pads will also allow food particles and sediment to pass through and clog the suction tube on the bottom of the filter pan. Particles large enough to block the suction tube may indicate that the crumb tray is not being used. Pan blockage can also occur if shortening is left in the pan and allowed to solidify. Blockage removal can be accomplished by forcing the item out with an auger or drain snake. Compressed air or other pressurized gases should not be used to force out the blockage. 7.9.2 Replacing the Filter Motor, Filter Pump, and Related Components 1. Remove the filter pan and lid from the unit. Drain the frypots into a Shortening Disposal Unit (SDU) or other appropriate metal container. DANGER DO NOT drain more than one full frypot or two split frypots into the SDU at one time. 2. Disconnect the fryer from the electrical power supply and reposition it to gain access to both the front and rear. 3. Disconnect the two flexlines running to the oil-return manifold at the rear of the fryer as well as the pump suction flexline at the end of the filter pan connection (see photo below). Disconnect flexlines indicated by the arrows. 7-10 4. Loosen the nut and bolt that secures the bridge to the oil-return manifold. 5. Remove the cover plate from the front of the motor and disconnect the motor wires. 6. Unplug the pump motor assembly 6-pin connector C-2 and, using a pin pusher, disconnect the vent vacuum-breaker solenoid (pins 2 and 5) that is attached to the oil return manifold. 7. Remove the two nuts and bolts that secure the front of the bridge to the cross brace and carefully slide the bridge rearward off the cross brace until its front end can be lowered to the floor. Undo the single nut holding it in place in back. Be careful not to let the rear of the bridge slip off the manifold at this point. 8. Get a good grip on the bridge, carefully pull it forward off the oil-return manifold, and lower the entire assembly to the floor. Once on the floor, pull the assembly out the front of the fryer. 9. When required service has been completed, reverse steps 6-12 to reinstall the bridge. NOTE: The black motor wires go on the top terminal, the white on the bottom. The pump solenoid valve wires go in positions 1 and 4 of the 6-pin connector C-2; the vent vacuum-breaker solenoid valve wires go in positions 2 and 5; the red/black heater tape wires go into position 3 and the violet/white wires go into position 6 (see illustration below). 10. Reconnect the unit to the electrical power supply, and verify that the pump is functioning correctly (i.e., when a filter handle is placed in the ON position, the motor should start and there should be strong suction at the intake fitting and outflow at the rear flush port.) 11. When proper operation has been verified, reinstall the back panels and the filter pan and lid. 12. Reposition the fryer under the exhaust hood and reconnect it to the electrical power supply to return the fryer to service. 7-11 7.9.3 Replacing the Filter Transformer or Filter Relay Remove the left controller from the fryer to expose the interior of the left component box. The filter transformer and relay are located as shown in the illustration below. NOTE: The right component box is identical to the left except that the filter transformer and relay are not present. Filter Relay Filter Transformer 7-12 7.10 Interface Board Diagnostic Chart The following diagram and charts provide ten quick system checks that can be performed using only a multimeter. Diagostic LEDs AL HI HTCMP24V HT HI AL J3 Diagnostic LED Legend 1 3 2 6 5 4 9 8 CMP indicates power from 12V transformer 24 indicates power from 24V transformer HI (RH) indicates output (closed) from right latch relay HI (LH) indicates output (closed) from left latch relay HT (RH) indicates output from right heat relay HT (LH) indicates output from left heat relay AL (RH) indicates output (open) from right latch relay AL (LH) indicates output (open) from left latch relay 7 12 11 10 15 14 13 J1 K1 K2 K3 K4 Left Latch Relay Left Heat Relay Right Heat Relay Right Latch Relay 12 9 6 3 12 9 6 3 11 8 10 7 5 4 2 1 11 8 10 7 5 4 2 1 J2 PN 106-6811 Test Points J1 Left J2 Right NOTE – When testing the test points on J1 and J2 test use the illustration above disregarding any silkscreened numbers on the board depicting the location of Pin 1. Pin 1 is located in the bottom right corner of Both J1 and J2. These test points are ONLY for RE Series boards with J1 and J2 plugs on the front of the board. Meter Setting 12 VAC Power 24 VAC Power *Probe Resistance (RH) *Probe Resistance (LH) High-Limit Continuity (RH) High-Limit Continuity (LH) Latch Contactor Coil (RH) Latch Contactor Coil (LH) Heat Contactor Coil (RH) Heat Contactor Coil (LH) Test 50 VAC Scale 50 VAC Scale R X 1000 OHMS R X 1000 OHMS R X 1 OHMS R X 1 OHMS R X 1 OHMS R X 1 OHMS R X 1 OHMS R X 1 OHMS Pin 3 of J2 2 of J2 11 of J2 1 of J1 9 of J2 6 of J1 8 of J2 5 of J1 7 of J2 4 of J1 Pin 1 of J2 Chassis 10 of J2 2 of J1 6 of J2 9 of J1 Chassis Chassis Chassis Chassis Results 12-16 VAC 24-30 VAC See Chart See Chart 0 - OHMS 0 - OHMS 3-10 OHMS 3-10 OHMS 18-25 OHMS 18-25 OHMS * Disconnect 15-Pin harness from the computer/controller before testing the probe circuit. 7-13 7.11 Probe Resistance Chart Probe Resistance Chart For use with fryers manufactured with Minco Thermistor probes only. F 60 65 70 75 80 85 90 95 100 105 110 115 120 125 OHMS 1059 1070 1080 1091 1101 1112 1122 1133 1143 1154 1164 1174 1185 1195 C 16 18 21 24 27 29 32 35 38 41 43 46 49 52 F 130 135 140 145 150 155 160 165 170 175 180 185 190 195 OHMS 1204 1216 1226 1237 1247 1258 1268 1278 1289 1299 1309 1320 1330 1340 C 54 57 60 63 66 68 71 74 77 79 82 85 88 91 F 200 205 210 215 220 225 230 235 240 245 250 255 260 265 OHMS 1350 1361 1371 1381 1391 1402 1412 1422 1432 1442 1453 1463 1473 1483 7-14 C 93 96 99 102 104 107 110 113 116 118 121 124 127 129 F 270 275 280 285 290 295 300 305 310 315 320 325 330 335 OHMS 1493 1503 1514 1524 1534 1544 1554 1564 1574 1584 1594 1604 1614 1624 C 132 135 138 141 143 146 149 152 154 157 160 163 166 168 F 340 345 350 355 360 365 370 375 380 385 390 395 400 405 OHMS 1634 1644 1654 1664 1674 1684 1694 1704 1714 1724 1734 1744 1754 1764 C 171 174 177 179 182 185 188 191 193 196 199 202 204 207 7.12 Wiring Diagram, System H14SC/H17SC/H22SC kW Single Fryers and FPH17SC kW Filter System Fryers 440-480V, 60 Hz, 3-Ø, 3-Wire Configurations Refer to page 2-2 for power requirements. 7-15 7.13 Wiring Diagram, Contactor Box H14SC/H17SC/H22SC kW Single Fryers and 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 cont. H14SC/H17SC/H22SC kW Single Fryers and FPH17SC kW Filter System Fryers 440-480V, 60 Hz, 3-Ø, 3-Wire Configurations Refer to page 2-2 for power requirements. 7-17 7.14 Wiring Diagram, Wiring Harness 7-18 7.15 Components Description of Operation A. Drain solenoid - When the return valve is opened, 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 solenoids releasing the vacuum. C. Full-vat oil return switch - When the return valve is open, the 24V circuit is closed and it activates the pump relay and drain solenoid. D. Dual-vat oil return switch - When the return valve is open, the 24V circuit is closed and it activates the pump relay and drain solenoid. E. Optional waste oil pump switch - The drain valves and oil return valves are closed. When the oil waste discharge valve is opened, the 24V circuit is closed, it activates the pump relay and drain solenoid. Safety interlock switch - The interlock switch is in series with the high-limit. It is actuated when the drain valve opens, which opens the latch circuit which drops out the 12V circuit on the interface board. This removes power from the latching contactor which opens and de-energizes the heating elements. F. 7-19 NAVY SURFACE SHIP ELECTRIC FRYERS CHAPTER 8: PARTS LIST 8.1 Accessories 1 3 2 4 5 6 7 9 8 ITEM PART # 1 809-0171 2 810-2793 3 809-0921 4 803-0197 5 803-0209 6 823-6009 7 806-4041 8 803-0132 9 803-0271 * 812-1226SP * 823-2109 * 803-0002 * 803-0170 * Not illustrated. 3 COMPONENT Thumbscrew, ¼ -20 X 1 /8-inch Hanger, Wireform Basket Spacer, Basket Hanger Cleanout Rod, 27-inch Brush, Frypot Connecting Strip, Frypot Cover, Full-Vat Frypot Rack, Full-Vat Basket Support Basket, Twin Drain Nipple 1¼-inch Painted Drain Pan, Military Powder, Filter (80-8oz. Applications) Paper, Filter (100-Sheet Pack) 8-1 8.2 Cabinetry 8.2.1 Backs, Control Panels, Doors, Handles, Sides, Tilt Housings & Top Caps 1 2 3 4 5 13 14 9 12 8 7 6 8-2 10 11 8.2.1 Backs, Control Panels, Doors, Handles, Sides, Tilt Housings & Top Caps (cont.) ITEM PART # COMPONENT 1 2 3 4 5 * 6 * * * * * * 7 8 9 * 10 11 * * * * 230-0675 230-0676 230-0677 230-0546 230-0672 230-0673 230-0674 230-0500 106-5016 106-5221 106-5018 106-7533 823-5567 823-5484 824-5493 823-6054 106-5195 106-5196 106-5197 106-7531 200-9614 200-9610 200-9611 106-4979 824-1516 210-9215 809-0500 826-1343 210-9188 106-4769 809-0266 210-9214 106-0554 826-1343 231-1558 231-0326 232-1558 232-0326 810-1105 809-0123 826-1376 809-0970 823-0839 823-2908 823-4585 823-6049 12 823-5440 13 230-2191 14 230-2097 230-2193 *Not illustrated. Back Panel, Upper - Single Two Station Fryer Three Station Fryer Four Station Fryer Back Panel, Center - Single Two Station Fryer Three Station Fryer Four Station Fryer Frame, Control Panel - Single Two Station Fryer Three Station Fryer Four Station Fryer Tilt Housing - Single Two Station Fryer Three Station Fryer Four Station Fryer Top Cap - Single Two Station Fryer Three Station Fryer Four Station Fryer Heat Shield - Single Two/Four Station Fryer Three Station Fryer Door Assembly - Single (includes items below plus 210-9214) Door, Universal Single Liner, Door Universal Single Screw, #10 – ½ Hex TR HD SS Spring, Door Pin Hinge (Pkg. of 10) Hinge, Door Single Door, Left or Right (Left shown – move handle to opposite side for Right) Two and Three Station Fryers Screw, #10 X ½-inch Phillips Truss Head Handle, Door Pin Assembly, Door Spring, Door Pin Hinge (Pkg. of 10) Side, Cabinet Left, Single Two or Three Station Side, Cabinet Right, Single Two or Three Station Magnet, Door Screw, #10 –3/4 Truss Slotted Head Nut KEPS 10-32 HX ZP (Pkg. of 10) Retaining Ring – Door Hinge Pin Handle (Grab Rail) – (For handle end use 910-0915) Single Station Fryer Two Station Fryer Three Station Fryer Four Station Fryer Cove, Element Tilt Housing Bezel, One-Controller Bezel, Two/Four-Controller Bezel, Three-Controller 8-3 8.2.2 Cabinets, Bases, Braces, and Associated Parts See Page 8-26 for rear bridge support/ oil return manifold See Page 8-22 through 8-24 for filter rails and associated hardware. 8-4 8.2.2 ITEM 1 2 3 4 5 6 Cabinet Bases, Braces, and Associated Parts (cont.) PART # COMPONENT 106-3828 Upright Assembly, Left 106-3829 Upright Assembly, Right 200-1651 Support, Cross Cabinet 200-1659 Divider, Cabinet 200-2293 Brace, Lower Front Brace, Front Horizontal 200-7036 Single-Station Fryer 200-7037 Two-Station Fryer 200-7038 Three-Station Fryer 200-7039 Four-Station Fryer 7 Brace, Rear Horizontal 200-5356 Single-Station Fryer 200-2284 Two-Station Fryer 200-2295 Three-Station Fryer 200-2725 Four-Station Fryer 8 222-0610 Bracket, Right Hand Mounting 9 221-0610 Bracket, Left Hand Mounting 10 200-4424 Post, Door 11 810-2346 Magnet, Door 12 210-6862 Hinge, Door 13 824-1488 Bracket, Rear Support 14 826-1389 Bolt, ¼-20 X ¾-inch Hex Head (Pkg. of 10) 15 826-1330 Screw, 10-32 X ⅜-inch Slotted (Pkg. of 25, used to attach contactor box) 16 826-1376 Nut, 10-32 Keps Hex (Pkg. of 10) 17 826-1374 Screw, #10 X ½-inch Hex Washer Head (Primary cabinet screw) Qty 25 18 809-0417 Nut, ¼-20 Hex Flange (used with item #22) 19 809-0429 Bolt, ¼-20 X 2-inch Hex Head 20 200-5417 Brace, Rear Channel Corner 21 Channel, Base Rear 823-5589 Single-Station Fryer (106-4901 Single Base Non-Filter Assembly) 823-4558 Two-Station Fryer (106-2744 - Double Base Assembly) 823-4560 Three-Station Fryer (106-2745 - Triple Base Assembly) 823-4561 Four-Station Fryer (106-2746 - Quad Base Assembly 22 824-1131 Channel, Base Side 23 200-4408 Support, Left Filter Pan 24 200-4409 Support, Right Filter Pan) 25 809-0079 Nutsert, ¼” - 20 26 809-0191 Washer, ¼” Lockspring 27 823-4386 Leg, Navy Shipboard (Mounts with Items 18 and 19) 28 231-0349 Side, LH Cabinet 29 232-0349 Side, RH Cabinet 30 809-0190 Washer, Flat 0.625”x 0.275”x 40 SS 31 220-1095 Support, Rear Contactor Box (use 220-1192 for Singles) 32 220-1093 Support, Front Contactor Box (use 220-1193 for Singles) * 823-4584 Bar, Filter Pan Lock * Not illustrated. 8-5 8.3 Drain System Components 8.3.1 Drain Tube Sections and Associated Parts 1 See next section for Drain Valve Detail 7 8 6 7 6 1 2 5 3 2 3 4 4 8-6 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 823-4643 Full-Vat 3” 823-4642 Dual-Vat 3” 3 Drain Tube, Right End Long 823-4639 Full-Vat 3” 823-4638 Dual-Vat 3” 4 Drain Tube, Left/Right Open Long 823-4641 Full-Vat 3” 823-4640 Dual-Vat 3” 5 823-4892 Drain Outlet Center Dump 6 816-0625 Sleeve 3” 7 809-0969 Clamp, 3” T-Bolt 8 810-2492 Fitting, Quick-Connect Straight (receives Teflon vent tube) * KIT6033 Kit, Round Drain Clamp (2 or Item 7 and 1 of Item 6) * 811-1071 Tube, Teflon Vent ¼-inch OD (sold by the foot) * Not illustrated. 8-7 8.3.2 Drain Valve Assembly and Assoc. Parts (Units with Built-In Filtration) ITEM 1 2 3 4 5 6 7 8 9 10 11 12 PART # 809-0540 900-2936 824-1602 816-0639 809-0237 901-2348 807-2103 816-0220 806-8137SP 106-5391 810-1018 810-1165 816-0135PK COMPONENT Nut, ½-13 2-Way Hex Lock Retainer, Full-Vat Nut Drain Valve Handle, Full-Vat Drain Valve Cap, Red Handle Nut, 4-40 Keps Hex Cover, Dual Vat Drain Safety Switch Microswitch, CE Straight Lever Insulation, Drain Safety Switch Bracket Assembly, Full-Vat Drain Safety Switch Bracket Assembly, Full-Vat Drain Safety Switch Single Footprint Only Valve, 1.25-inch Full-Vat Drain Single Footprint Only Washer, Teflon O-Ring, Round Drain (Qty. 4) 8-8 8.3.2 Drain Valve Assembly and Assoc. Parts cont. (Units with Built-In Filtration) ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 PART # 809-0540 900-2936 824-1602 816-0639 809-0237 901-2348 807-2103 816-0220 810-1165 200-6496 806-8137 810-1018 816-0135PK COMPONENT Nut, ½-13 2-Way Hex Lock Retainer, Full-Vat Drain Valve Nut Handle, Full-Vat Drain Valve Cap, Red Handle Nut, 4-40 Keps Hex Cover, Dual Vat Drain Safety Switch Microswitch, CE Straight Lever Insulation, Drain Safety Switch Washer, Teflon Drain Valve Support, 3” Drain Bracket Assembly, Full-Vat Drain Safety Switch Valve, 1.25-inch Full-Vat Drain Round Drain O-Ring (Qty. 4) 8-9 8.3.2 Drain Valve Assembly and Assoc. Parts cont. (Units with Built-In Filtration) 8-10 8.3.2 Drain Valve Assembly and Assoc. Parts cont. (Units with Built-In Filtration) ITEM 1 2 3 4a 4b 5 6 7 8 9 10 11 PART # 816-0639 809-0539 900-2934 824-1636 824-1637 809-0237 901-2348 807-2103 816-0220 810-1165 809-0196 106-2671 106-6304 12 810-1114 13 816-0135PK * 823-5592 * Not illustrated. COMPONENT Cap, Drain Handle Nut, ⅜-16 2-Way Hex Lock Retainer, Dual-Vat Drain Valve Nut Handle, Dual-Vat Right Drain Valve Handle, Dual-Vat Left Drain Valve Nut, 4-40 Keps Hex Cover, Dual Vat Drain Safety Switch Microswitch, CE Straight Lever Insulation, Drain Safety Switch Washer, Teflon Drain Valve Washer, ⅜-inch Flat Bracket Assembly, Dual-Vat Drain Safety Switch Bracket Assembly, Dual-Vat Drain Safety Switch Single Footprint Only Valve, 1-inch Dual-Vat Drain Round Drain O-Ring (Qty 4) Tube, Drain Single-Station Only with Filter 8.3.3 Drain Valves and Associated Parts (Units without Built-In Filtration) 1 4 2 3 5 ITEM 1 2 3 4 5 PART # 810-1569 806-7915SP 806-7916SP 812-1226 812-1227 COMPONENT Valve, 1.25-inch Non-Filter Full-Vat Drain Valve, 1-inch Non-Filter Dual-Vat Left Drain Valve, 1-inch Non-Filter Dual-Vat Right Drain Drain Extension, 1.25-inch Drain Extension, 1-inch 8-11 8.4 8.4.1 Electronics and Wiring Components Component Boxes NOTE 1: The transformer on the left side of the component box (Item 11) and the relay (Item 5) are present only in the left component box. NOTE 2: See Page 8-19 for Component Box 15-pin Wiring Harness. ITEM 1 2 3 4 5 6 7 8 9 10 11 * 12 13 PART # 106-5846 210-9002 230-1057 806-9495SP 807-0012 826-1337 810-0045 807-1947 810-2446 807-0855 807-0800 807-3892 809-0349 106-6811 807-3932 * 807-4330 * 806-7179SP 14 106-5848 15 807-0069 16 210-9118 17 810-2445 * Not illustrated. COMPONENT Box Assembly, Component Bracket, Component Box Strain Relief Bracket, Circuit Breaker Terminal Block and Wire Assembly Relay, Filter 18 Amp ⅓ HP 24V Coil Terminal, ¼-inch Push-on (Pkg. of 5) Bushing, .875 Dia. Hole 11/16” Plug, .875 Plug, .50 Heyco Double “D” Transformer, 100-120V/12V 20VA Transformer, 100-120V/24V 50VA Transformer, 440/480 12/24V (Used in non-filter fryers) Spacer, 4mm X 6mm Aluminum Interface Board (on SMT boards the Relays are not replaceable) Relay, Heat/Latch 12VDC SPDT 12 Amp Sealed (on SMT boards the Relays are not replaceable) Sound Device Adaptor Harness Sound Device (use 810-3141 for SMT Sound Device) Handle Assembly, Oil Flush FV Circuit Breaker, 10 Amp Guard, Finger Plug, Button .625 Heyco Double “D” Continued on the following page. 8-12 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, Insulating Terminal Block CE 23 106-5750 Harness, Full Vat Assembly 24 220-0083 Plate, Strain Relief 25 807-4036 Switch 807-3575 Plug, Carling Switch Hole (used in place of a switch on some models) 26 230-0834 Guard, RE Box Switch * Not illustrated. 8-13 8.4.2 Contactor Boxes NOTE 1: Left and right contactor box assemblies are mirror images of one another. With the exception of the box itself, all components of a left-hand assembly, are the same as those in the corresponding right-hand assembly and vice versa. NOTE 2: See Page 8-18 and 8-19 for Contactor Box Wiring Assembly 8-14 8.4.2 Contactor Boxes cont. ITEM 1 2 3 4 5 PART # 106-6278 106-6279 106-6292 106-6268 106-6124 106-6125 106-6288 106-6255 807-0031 807-0064 6 807-2284 7 810-1202 8 807-2283 9 807-2434 10 807-1683 11 807-0012 12 807-0922 13 807-2278 14 231-1135 15 232-1135 16 230-1377 17 220-1089 18 220-1088 19 220-1087 20 807-0070 21 807-3970 * 231-0811 * WIR0751 * WIR0726 * WIR0712 * 232-0811 *Not illustrated. COMPONENT Assembly, Contactor Box Left Assembly, Contactor Box Right Assembly, Contactor Box Single Assembly, Contactor Box Large (Not over the filter-pan box) Box, Left Contactor Box, Right Contactor Box, Single Footprint Contactor Box, Large Contactor (Not over the filter-pan box) Transformer, 250VA Transformer, 480V/120V 150 VA (used in fryers with filtrations systems only) Contactor, 24V 50 Amp Mechanical (used in 14 & 17kW units only) Contactor, 24V 40 Amp Mechanical Contactor, 24V 63 Amp Mechanical (used in 22kW units only) Relay, Shunt 24V Coil Amp Relay, Power 12 VDC Relay, Tilt 18 Amp HP 24 V Coil Holder, Bus Fuse Fuse, 20 Amp Cover, Left Hand Cover, Right Hand Cover, Single Foot Print Cover, Large Top Cover, Contactor Box Front Bracket, Box Connecting Terminal, Ground Lug Block, Terminal 3 pole 600V 175A (used in 22kW only) Bracket, Left Hand Contactor Box Mounting Wire Assembly, Filter Shunt Relay Wire Assembly, Hood Relay Wire Assembly, Latch/Heat Jumpers Bracket, Right Hand Contactor Box Mounting 8-15 8.4.3 Heating Element Assembly and Associated Parts 8 10 12 19 18 17 14 13 15 17 16 9 3 12 11 5 4 7 27 4 20 21 2 1 1 6 26 28 29 30 23 21 22 24 25 NOTES: The only difference between element assemblies for different voltage and kW ratings is the element itself (Item 1). Items 28, 29 and 30 are shown as associated parts. They are not part of either assembly. This manual references only the new “RE” element. For previous model fryers and related parts prior to May 2006 see manual 819-5184. 8-16 8.4.3 Heating Element Assembly and Associated Parts (cont.) ITEM 1 PART # 826-2195 826-2202 826-2211 826-2196 826-2203 826-2209 2 826-2212 3 816-0681 4 816-0480 5 816-0688 6 810-2971 7 809-0567 8 106-5590 9 106-5588 10 106-5589 11 230-0554 12 230-0553 13 106-6569 14 106-6570 15 826-1330 16 809-0766 17 809-1000 18 106-6037 19 810-2993 20 230-0850 21 809-0518 22 210-9180 23 230-0781 24 230-0849 25 823-5657 26 826-1364 27 809-1003 28 810-3030 810-3031 29 220-0464 220-1190 30 220-0733 * 106-6587 * 810-3007 * 230-0794 * Not illustrated. COMPONENT Element Kits – includes gaskets, grommets, tie wraps, screws and nuts. 440V 17.0 kW 440V 18.5 kW 440V 11.0 kW 480V 17.0 kW 480V 18.5 kW 480V 11.0 kW Probe, Temperature Kit (includes tie wraps and grommet) Grommet, Probe Plug, .375-inch Dome Gasket, Element Handle, Element Lift SS Tie-Wrap, Metal Tube Assembly Element, Full-Vat Bracket Assembly, LH Element Tube Support Bracket Assembly, RH Element Tube Support Plate, Element Tube Support Inner Plate, Element Tube Support Outer Bracket Assembly, LH Upper Spring Bracket Assembly, RH Upper Spring Screw, 10-32 X ⅜-inch Slotted Truss Head SS (Pkg. of 25) Nut, 10-32 Hex HD SS Screw, 10-32 x 1¼-inch Hex Tube, FV Element Mounting Bushing, Tube End Teflon Bracket, Temperature Probe Screw, 8-32 X ⅜-inch Slotted Hex Head SS Clamp, Element (Short) Clamp, Element (Long) Bracket RE, Full-Vat Element Rear Bracket RE, Full-Vat Element Front Pin, .125 X .5-inch Split (Pkg. of 25) Screw, 10-32 X ⅜-inch Hex Head SS (uses 809-0766 nut 10-32 SS) Spring, Element Lift Left Spring, Element Lift Right Bracket, Lower Spring Bracket, Lower Spring Single Foot Print Bracket, Lower Spring Mating Magnetic Position Sensor Magnet Bracket, Magnetic Position Sensor Wire 8-17 8.4.4 Controller Controller P/N 806-3798 Knob P/N 810-0387 Power Switch P/N 807-0812 High-Limit Switch P/N 807-0811 8.4.5 Wiring 8.4.5.1 Contactor Box Wiring Assembly – 12-Pin Full-Vat C-1 8.4.5.2 Contactor Box Wiring Assemblies – 6-Pin (Left Element) 8-18 8.4.5.3 Contactor Box Wiring Assemblies – 9-Pin (Right Element) 8.4.5.4 Main Wiring Harness 8.4.5.5 Component Box and Filter Pump Wiring Harnesses ITEM 1 PART # 106-5750 2 106-5935 COMPONENT Full Vat Control Harness J4 to J2 (WIR0765 – Navy Jumper Wire Kit is needed with this harness) Filter Pump C2 to Component Box Wiring Harness 8-19 8.4.5.6 Interface Board to Controller Wiring Harness – 15-Pin PN 806-2071SP Standard Controller to Interface Board 8-20 8.5 Filtration System Components 8.5.1 FPH17 Filtration Components 8-21 8.5.1 FPH17 Filtration Components (cont.) ITEM PART # 106-5983 1 106-6243 2 824-1707 3 823-5774 4 220-1316 5 823-5594 6 810-2198 * 826-1979 * 826-1372 * 810-2012 7 826-1392 8 106-5981 9 106-5982 10 823-5591 11 826-1270 12 826-1264 810-2716 816-0093 * 807-11973 13 810-1668 14 810-1680 15 813-0165 16 813-0298 17 810-1669 * 106-2852SP * Not illustrated. COMPONENT Assembly, Filter Pan Single includes pan and lid Lid, Single Crumb Tray Hold Down Ring - Paper Sana Grid Filter Screen Pan, Filter Roller, Filter Pan Rail (used with Item 8 and 9) Filter Pan Roller Kit (four each of Items 6 and 826-1372) Nut, ¼-20 Hex (Pkg. of 10) Rail Set, Filter Pan Roller (includes one left and one right) O-Ring (Pkg. of 5; used with Item 5) Support, Assy. Left Filter Pan Support, Assy. Right Filter Pan Fitting, Female Suction Tube Motor and Gasket Kit, 220-240V 50/60Hz Pump and Gasket Kit Pump, Viking 4GPM 2-piece Gasket, Pump/Motor Viking Pump Seal Kit Adapter, ⅝-inch to ½-inch NPT Male Flexline, 6.5-inch Oil Return Elbow, ST ½-inch x ½-inch NPT 90° BM Nipple, ½-inch 2.0-inch Adapter, ⅝-inch to ½-inch NPT Female Heater Strip Assembly, 208-250V 25W 18” 8-22 8.5.2 Multiple Battery Filtration System Components 1 19 18 35 24 29 34 2 33 17 25 20 27 18 26 24 22 16 30 3 23 21 28 32 8 10 9 11 12 11 12 8 14 4 31 7 6 15 5 13 8-23 25 8.5.2 Multiple Battery Filtration System Components (cont.) ITEM PART # * * * * * * * 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 826-1979 826-1980 826-1981 826-1392 813-0568 811-1071 806-5933SP 823-4787 810-2743 810-2910 200-2124 106-2617SP 810-2012 810-2198 826-1372 823-4675 200-3556 809-0503 809-0247 823-3879 200-4408 200-4409 826-1712 826-1264 816-0093 807-11973 807-2484 813-0165 813-0342 813-0530 813-0022 813-0838 813-0304 810-1668 810-1669 810-1159 810-1057 810-1055 807-3828 826-1375 200-7112 813-0003 813-0298 813-0537 810-1043 * 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 * COMPONENT Filter Pan Roller Kit (four each of Items 7 and 8) Service Filter Pan (Item 5 minus Item 2) Service Filter Pan Assembly (Service Filter Pan above plus Items 3 & 4) O-Ring (Pkg. of 5; used with Item 5) Plug, ⅛-inch Socket Head Pipe (component of Item 5; two required) Tubing, ¼-inch OD Teflon Vent (sold by the foot) Heater Strip Assembly, 120V 18” 25W Lid Crumb Tray (component of Item 5) Hold Down Ring SanaGrid Filter Screen Pan, One-Piece Filter (includes Item 2) Rail Set, Filter Pan Roller (includes one left and one right) Roller, Filter Pan and Rail Nut, ¼-20 Hex (Pkg. of 10) Bracket, Lid Support Guide, Filter Pan Lid Screw, 8-32 X ½-inch Slotted Truss Head Nut, 8-32 Hex Keps Suction Tube Rail, Left Filter Rail, Right Filter Kit, Motor and Gasket 115V 60Hz Pump and Gasket Kit 4 GPM 2-piece Gasket, Pump/Motor Pump Seal Kit Valve, ¼-inch Solenoid Elbow, ½-inch 90° Street Elbow, ½-inch 45° Street Tee, ½-inch X ¼-inch X ½-inch Reducing Nipple, ½-inch Close Nipple, ¼-inch Close Bushing, ½-inch to ¼-inch Flush Adapter, ⅝-inch to ½-inch NPT Male Adapter, ⅝-inch to ½-inch NPT Female Flexline, 5.0-inch Oil Return Flexline, 13.0-inch Oil Return Flexline, 11.5-inch Oil Return Cable, FootPrint Pro Pump Motor Screw, 10-32 X ¾-inch Hex Trim Head (Pkg. of 5) Bridge, Filter Motor Tee, ½-Inch Nipple, ½-inch 2.0-inch Nipple, ¼-inch 2.0-inch Flexline, 9.5-inch Oil Return * Not illustrated. 8-24 8.6 Frypot Assembly and Thermostat Thermostat P/N 806-7543 Frypot P/N 823-5359SP 8-25 8.7 Oil Return System Components 8-26 8.7 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13a 13b 14 15 16 17 18 19 20 Oil Return System Components (cont.) PART # 106-5848 813-0907 807-2103 106-5847 210-8998 816-0220 826-1366 810-3034 816-0643 809-0601 810-2532 810-1668 813-0165 813-0908 810-2944 200-5438 900-2935 813-0460 810-3015 810-3016 810-3017 COMPONENT Handle Assembly Cap, 15/16-inch Valve Safety Microswitch, Straight Lever Bracket Assembly, Microswitch Bracket, Handle Retainer Insulation, Oil Return Microswitch Nut, 4-40 Keps Hex (Pkg. of 25) Rod, Filter Handle Grip, Oil Return Valve Handle Clip, Clevis Flexline, 7.0-inch Adapter, ⅝-inch to ½-inch NPT Male Elbow, ½-inch X 90° Street Adapter, ½-inch NPT M/T 90º (used only on side next to cabinet) Valve, ½-inch Ball Handle, Rear Flush Valve Retainer, Oil Return Valve Nut Nipple, ½-inch X 3.0-inch NPT Manifold, Two-Station Fryer (use 810-2543 for non-filter units) Manifold, Three-Station Fryer (use 810-2544 for non-filter units) Manifold, Four-Station Fryer (use 810-2545 for non-filter units) 8-27 8.8 Wiring Connectors, Pin Terminals and Power Cords 1 6 11 ITEM PART # * * 807-3834 807-3825 1 807-1068 2 807-0158 3 807-0156 5 807-0159 5 807-0875 6 807-1067 7 807-0157 8 807-0155 9 807-0160 10 807-0804 11 826-1341 12 826-1342 13 807-2518 * Not illustrated. 2 3 7 8 12 5 4 9 10 13 COMPONENT Power Cords Cable, 3-Phase 4-Wire (Fryer Power Cable) Cord, Filter System Power Connectors 2-Pin Female 6-Pin Female 9-Pin Female 12-Pin Female 15-Pin Female 2-Pin Male 6-Pin Male 9-Pin Male 12-Pin Male 15-Pin Male Terminal, Female Split Pin (Pkg of 25) Terminal, Male Split Pin (Pkg of 25) Plug, Mate-N-Lock (Dummy Pin) 8-28 8.9 Fasteners ITEM * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * PART # 809-0429 809-0514 809-0448 826-1366 826-1358 809-0247 826-1376 809-0766 809-0581 809-0020 826-1372 809-0417 809-0535 809-0540 826-1359 826-1365 809-0357 809-0359 809-0360 826-1371 809-0364 809-0518 809-0104 826-1363 826-1360 826-1330 809-1003 826-1375 809-1000 826-1374 809-0266 809-0434 809-0123 826-1389 809-0582 809-0184 809-0190 809-0191 809-0193 809-0194 COMPONENT Bolt, ¼-inch – 20 x 2.00-inch Hex Head ZP Tap Capscrew, 5/16-inch-18 NC Hex Clip, Tinnerman Nut, 4-40 Keps Hex (Pkg. of 25) (809-0237) Nut, 6-32 Keps Hex (Pkg. of 25) (809-0049) Nut, 8-32 Keps Hex Nut, 10-32 Keps Hex (Pkg. of 10) (809-0256) Nut, 10-32 Keps Hex SS Nut, ½ NPT Locking Nut Cap 10-24 NP Nut Grip ¼-inch 1/4-20 Hex NP (Pkg. of 10) (809-0059) Nut Flange ¼-inch 1/4-20 Serr Nut, "T" ¼-inch-20 x 7/16 SS Nut, Lock ½-inch-13 Hex 2-Way ZP Screw, 4-40 x ¾-inch Slotted Round Head (Pkg. of 25) (809-0354) Screw, 6-32 x ⅜-inch Slot Head (Pkg. of 25) (809-0095) Screw, 6 x ⅜-inch Phillips Head NP Screw, 8 x ¼-inch Hex Washer Head Screw, 8 x ⅜-inch Hex Washer Slot Head Screw, 8 x ½-inch Hex Head ZP (Pkg. of 25) (809-0361) Screw, 8 x ⅝-inch Hex Washer Head ZP Screw, 8-32 x ⅜-inch Hex Washer Slotted Head SS Screw, 8-32 x ½-inch Slotted Head ZP Screw, 8-32 x ½-inch NP (Pkg. of 25) (809-0103) Screw, 10-24 x 5/16-inch Round Slot Head ZP (Pkg. of 25) (809-0024) Screw, 10-32 x ⅜-inch Slot Head SS (809-0117) Screw, 10-32 x ⅜-inch Hex Trim Head SS Screw, 10-32 x ¾-inch Hex Trim Head SS (Pkg. of 5) (809-0401) Screw, 10-32 x 1¼-inch Hex Sck C/S Screw, 10 x ½-inch Hex Head (Pkg. of 25) (809-0412) Screw, 10 x ½-inch Phillips Head ZP Screw, 10 x ⅜-inch Hex Washer Head NP Screw, 10 x ¾-inch Slot Head Screw, 1/4-20 x ¾-inch Hex Head ZP (Pkg. of 10) (809-0131) Washer ½ NPT Locking Washer, #10 LK ZP Washer, .625 X .275 X 40 Flat SS Washer, Lock 1/4 Spring ZP Washer, Flat 1/4 Nylon Washer, Flat 5/16 ZP 8-29 THIS PAGE INTENTIONALLY LEFT BLANK Frymaster, L.L.C., 8700 Line Avenue, Shreveport, LA 71106 TEL 1-318-865-1711 FAX (Parts) 1-318-688-2200 PRINTED IN THE UNITED STATES SERVICE HOTLINE 1-800-551-8633 (Tech Support) 1-318-219-7135 819-6203 NOVEMBER 2008
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