Frymaster 8196203 Installation, Operation, Service, And Parts Manual
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Frymaster 8196203 Installation, Operation, Service, And Parts Manual

Frymaster 8196203 Installation, Operation, Service, And Parts Manual

Navy surface ship electric fryers
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This manual is applicable to fryers manufactured beginning
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.
www.frymaster.com
Frymaster, a member of the Commercial Food Equipment Service Association, recommends
using CFESA Certified Technicians.
24-Hour Service Hotline 1-800-551-8633
E-mail:
service@frymaster.com
May 2006
with serial
*8196203*
NOV 08

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Summary of Contents for Frymaster 8196203

  • Page 1 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.
  • Page 2 Frymaster optional equipment casters must be used. Questions? Call 1-800-551-8633 or email at service@frymaster.com 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.
  • Page 3 Manual of the U.S. Food and Drug Administration. 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 This device complies with Part 15 of the FCC rules.

  • Page 4: Table Of Contents

    Navy Surface Ship Electric Fryers Installation, Operation, Service, and Parts Manual TABLE OF CONTENTS Chapter 1: Introduction Chapter 2: Installation Instructions Chapter 3: Operating Instructions Chapter 4: Filtration Instructions Chapter 5: Preventive Maintenance Chapter 6: Operator Troubleshooting Chapter 7: Service Procedures Chapter 8: Parts List Page...

  • Page 5: Chapter 1: Introduction

    Throughout this manual, you will find notations enclosed in double-bordered boxes similar to the one below. 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.
  • Page 6 15 days of date of delivery. Be sure to retain container for inspection. 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.

  • Page 7: Chapter 2: Installation Instructions

    167°F (75°C). 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.
  • Page 8 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.
  • Page 9 3. Position the fryer on the deck studs and secure with appropriate nuts and lock washers. 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.
  • Page 10 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.
  • Page 11 33.38 28.29 17.534 2.465 20.48 15.67 10.580 20.48 Mounting Holes Ø .625, 4 Places Single Fryer (non-filter) 2.470 26.316 Back of Fryer Unit 7.098 Typical 31.62 31.62 33.39 17.515 Mounting Holes Ø .625, 4 Places Front Handle 31.45 2-Fryer Battery...
  • Page 12 7.229 32.66 17.516 2.470 26.320 7.119 31.61 17.490 27.570 Back of Fryer Unit 32.66 Front Handle 47.1 3-Fryer Battery 62.55 Back of Fryer Unit 31.61 35.76 Front Handle 4-Fryer Battery 14.400 22.66 22.66 33.24 Mounting Holes Ø .625, 4 Places 31.180...

  • Page 13: Chapter 3: Operating Instructions

    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.
  • Page 14 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...
  • Page 15 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.
  • Page 16 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.

  • Page 17: Chapter 4: Filtration Instructions

    O-rings are in good condition. O-rings are located on the tube disconnect inside the filter pan as shown to the right. WARNING Rotate the locking rod to either side to allow the pan to be pulled out from the fryer. Inspect O-Rings...
  • Page 18 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.
  • Page 19 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.
  • Page 20 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.

  • Page 21: Chapter 5: Preventive Maintenance

    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.
  • Page 22 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.
  • Page 23 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. Check Calibration of Temperature Control Knob –...
  • Page 24 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 •...
  • Page 25 • 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. •...

  • Page 26: Chapter 6: Operator Troubleshooting

    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.
  • Page 27 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.
  • Page 28 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.
  • Page 29 C. Blockage in filter pump. Test: Close the drain valve and pull the filter pan out from the fryer. Activate the pump. If the pump motor hums for a short time then stops, the probable cause is blockage of the pump itself.
  • Page 30 Filter pump runs but oil does not Test: Close the drain valve and pull return to frypot and the filter pan out from the fryer. Activate the pump. If bubbling oil there is no bubbling oil. occurs, there is a blockage in the filter pan suction tube.

  • Page 31: Chapter 7: Service Procedures

    NAVY SURFACE SHIP ELECTRIC FRYERS CHAPTER 7: SERVICE PROCEDURES 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.
  • Page 32 (SDU) or other appropriate metal container. 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.
  • Page 33 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.
  • Page 34 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.
  • Page 35 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.
  • Page 36 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.
  • Page 37 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.
  • Page 38 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).
  • Page 39 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. 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.
  • Page 40 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).
  • Page 41 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.
  • Page 42 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.

  • Page 43: Interface Board Diagnostic Chart

    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 Left Left Right Latch Heat Heat Relay Relay Relay Test Points J1 Left J2 Right NOTE –...

  • Page 44: Probe Resistance Chart

    7.11 Probe Resistance Chart Probe Resistance Chart For use with fryers manufactured with Minco Thermistor probes only. OHMS OHMS 1059 1204 1070 1216 1080 1226 1091 1237 1101 1247 1112 1258 1122 1268 1133 1278 1143 1289 1154 1299 1164 1309 1174 1320...
  • Page 45 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...
  • Page 46 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...
  • Page 47 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...
  • Page 48 7.14 Wiring Diagram, Wiring Harness 7-18...
  • Page 49 7.15 Components Description of Operation When the return valve is opened, a microswitch activates A. Drain solenoid - and supplies 24V to the pump relay and solenoids. Vacuum release When the return valve is closed, it de-energizes the 24V to solenoid - the pump relay and solenoids releasing the vacuum.

  • Page 50: Chapter 8: Parts List

    NAVY SURFACE SHIP ELECTRIC FRYERS CHAPTER 8: PARTS LIST Accessories ITEM PART # 809-0171 Thumbscrew, ¼ -20 X 1 810-2793 Hanger, Wireform Basket 809-0921 Spacer, Basket Hanger 803-0197 Cleanout Rod, 27-inch 803-0209 Brush, Frypot 823-6009 Connecting Strip, Frypot 806-4041 Cover, Full-Vat Frypot 803-0132 Rack, Full-Vat Basket Support 803-0271...
  • Page 51 Cabinetry 8.2.1 Backs, Control Panels, Doors, Handles, Sides, Tilt Housings & Top Caps...
  • Page 52 8.2.1 Backs, Control Panels, Doors, Handles, Sides, Tilt Housings & Top Caps (cont.) ITEM PART # 230-0675 Back Panel, Upper - Single 230-0676 Two Station Fryer 230-0677 Three Station Fryer 230-0546 Four Station Fryer 230-0672 Back Panel, Center - Single...
  • Page 53 8.2.2 Cabinets, Bases, Braces, and Associated Parts See Page 8-22 through 8-24 for filter rails and associated hardware See Page 8-26 for rear bridge support/ oil return manifold...
  • Page 54 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 Brace, Rear Horizontal 200-5356 Single-Station Fryer 200-2284...
  • Page 55 Drain System Components 8.3.1 Drain Tube Sections and Associated Parts See next section for Drain Valve Detail...
  • Page 56 8.3.1 Drain Tube Section and Associated Parts (cont.) ITEM PART# Drain Tube, Left/Right End Short 823-4625 Full-Vat 3” 823-4624 Dual-Vat 3” Drain Tube, Left/Right Open Short 823-4643 Full-Vat 3” 823-4642 Dual-Vat 3” Drain Tube, Right End Long 823-4639 Full-Vat 3” 823-4638 Dual-Vat 3”...
  • Page 57 8.3.2 Drain Valve Assembly and Assoc. Parts (Units with Built-In Filtration) ITEM PART # 809-0540 Nut, ½-13 2-Way Hex Lock 900-2936 Retainer, Full-Vat Nut Drain Valve 824-1602 Handle, Full-Vat Drain Valve 816-0639 Cap, Red Handle 809-0237 Nut, 4-40 Keps Hex 901-2348 Cover, Dual Vat Drain Safety Switch 807-2103...
  • Page 58 8.3.2 Drain Valve Assembly and Assoc. Parts cont. (Units with Built-In Filtration) ITEM PART # 809-0540 Nut, ½-13 2-Way Hex Lock 900-2936 Retainer, Full-Vat Drain Valve Nut 824-1602 Handle, Full-Vat Drain Valve 816-0639 Cap, Red Handle 809-0237 Nut, 4-40 Keps Hex 901-2348 Cover, Dual Vat Drain Safety Switch 807-2103...
  • Page 59 8.3.2 Drain Valve Assembly and Assoc. Parts cont. (Units with Built-In Filtration) 8-10...
  • Page 60 8.3.2 Drain Valve Assembly and Assoc. Parts cont. (Units with Built-In Filtration) ITEM PART # 816-0639 Cap, Drain Handle 809-0539 Nut, ⅜-16 2-Way Hex Lock 900-2934 Retainer, Dual-Vat Drain Valve Nut 824-1636 Handle, Dual-Vat Right Drain Valve 824-1637 Handle, Dual-Vat Left Drain Valve 809-0237 Nut, 4-40 Keps Hex 901-2348...
  • Page 61 Electronics and Wiring Components 8.4.1 Component Boxes NOTE 1: 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 PART # 106-5846 Box Assembly, Component 210-9002...
  • Page 62 8.4.1 Component Boxes cont. ITEM PART# 210-8995 Brace, Component Box 807-1083 Bushing, Heyco 807-3868 Strain Relief 807-0121 Bushing, Heyco SB-625-500 816-0217 Paper, Insulating Terminal Block CE 106-5750 Harness, Full Vat Assembly 220-0083 Plate, Strain Relief 807-4036 Switch 807-3575 Plug, Carling Switch Hole (used in place of a switch on some models) 230-0834 Guard, RE Box Switch * Not illustrated.
  • Page 63 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...
  • Page 64 8.4.2 Contactor Boxes cont. ITEM PART # 106-6278 Assembly, Contactor Box Left 106-6279 Assembly, Contactor Box Right 106-6292 Assembly, Contactor Box Single 106-6268 Assembly, Contactor Box Large (Not over the filter-pan box) 106-6124 Box, Left Contactor 106-6125 Box, Right Contactor 106-6288 Box, Single Footprint Contactor 106-6255...
  • Page 65 8.4.3 Heating Element Assembly and Associated Parts 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”...
  • Page 66 8.4.3 Heating Element Assembly and Associated Parts (cont.) ITEM PART # Element Kits – 826-2195 440V 17.0 kW 826-2202 440V 18.5 kW 826-2211 440V 11.0 kW 826-2196 480V 17.0 kW 826-2203 480V 18.5 kW 826-2209 480V 11.0 kW 826-2212 Probe, Temperature Kit (includes tie wraps and grommet) 816-0681 Grommet, Probe 816-0480...
  • Page 67 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...
  • Page 68 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 PART # 106-5750 Full Vat Control Harness J4 to J2 (WIR0765 – Navy Jumper Wire Kit is needed with this harness) 106-5935 Filter Pump C2 to Component Box Wiring Harness COMPONENT...
  • Page 69 8.4.5.6 Interface Board to Controller Wiring Harness – 15-Pin PN 806-2071SP Standard Controller to Interface Board 8-20...
  • Page 70 Filtration System Components 8.5.1 FPH17 Filtration Components 8-21...
  • Page 71 8.5.1 FPH17 Filtration Components (cont.) ITEM PART # 106-5983 Assembly, Filter Pan Single includes pan and lid 106-6243 Lid, Single 824-1707 Crumb Tray 823-5774 Hold Down Ring - Paper 220-1316 Sana Grid Filter Screen 823-5594 Pan, Filter 810-2198 Roller, Filter Pan Rail (used with Item 8 and 9) 826-1979 Filter Pan Roller Kit (four each of Items 6 and 826-1372) 826-1372...
  • Page 72 8.5.2 Multiple Battery Filtration System Components 8-23...
  • Page 73 8.5.2 Multiple Battery Filtration System Components (cont.) ITEM PART # 826-1979 Filter Pan Roller Kit (four each of Items 7 and 8) 826-1980 Service Filter Pan (Item 5 minus Item 2) 826-1981 Service Filter Pan 826-1392 O-Ring (Pkg. of 5; used with Item 5) 813-0568 Plug, ⅛-inch Socket Head Pipe (component of Item 5;...
  • Page 74 Frypot Assembly and Thermostat Thermostat P/N 806-7543 Frypot P/N 823-5359SP 8-25...
  • Page 75 Oil Return System Components 8-26...
  • Page 76 Valve, ½-inch Ball 200-5438 Handle, Rear Flush Valve 900-2935 Retainer, Oil Return Valve Nut 813-0460 Nipple, ½-inch X 3.0-inch NPT 810-3015 Manifold, Two-Station Fryer 810-3016 Manifold, Three-Station Fryer 810-3017 Manifold, Four-Station Fryer COMPONENT (Pkg. of 25) (use 810-2543 for non-filter units)
  • Page 77 807-1067 807-0157 807-0155 807-0160 807-0804 826-1341 826-1342 807-2518 * Not illustrated. COMPONENT Cable, 3-Phase 4-Wire (Fryer Power Cable) Cord, Filter System Power 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...
  • Page 78 Fasteners ITEM PART # 809-0429 Bolt, ¼-inch – 20 x 2.00-inch Hex Head ZP Tap 809-0514 Capscrew, 5/16-inch-18 NC Hex 809-0448 Clip, Tinnerman 826-1366 Nut, 4-40 Keps Hex (Pkg. of 25) (809-0237) 826-1358 Nut, 6-32 Keps Hex (Pkg. of 25) (809-0049) 809-0247 Nut, 8-32 Keps Hex 826-1376...
  • Page 79 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 80 Frymaster, L.L.C., 8700 Line Avenue, Shreveport, LA 71106 TEL 1-318-865-1711 FAX (Parts) 1-318-688-2200 (Tech Support) 1-318-219-7135 819-6203 SERVICE HOTLINE NOVEMBER 2008 PRINTED IN THE UNITED STATES 1-800-551-8633...

This manual is also suitable for:

H14scH17scH22scFph17sc series

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