Frymaster FGP55 Series Service & Parts Manual
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Frymaster FGP55 Series Service & Parts Manual

Frymaster FGP55 Series Service & Parts Manual

Rethermalizer
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NON-CE &
Frymaster, a member of the Commercial Food Equipment Service Association, recommends
using CFESA Certified Technicians.
OCTOBER 2006
24-Hour Service Hotline
*8196250*
1-800-551-8633
www.frymaster.com
Email:
service@frymaster.com

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Summary of Contents for Frymaster FGP55 Series

  • Page 1 NON-CE & Frymaster, a member of the Commercial Food Equipment Service Association, recommends using CFESA Certified Technicians. OCTOBER 2006 24-Hour Service Hotline *8196250* 1-800-551-8633 www.frymaster.com Email: service@frymaster.com...
  • Page 2 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.
  • Page 3 COMPUTERS 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.

  • Page 4: Table Of Contents

    FGP55 Series Rethermalizers Service & Parts Manual TABLE OF CONTENTS Page # SERVICE PROCEDURES Functional Description Accessing Fryers for Service Cleaning the Gas Valve Vent Tube (if applicable) Adjusting Burner Manifold Gas Pressure Adjusting the Pilot Flame Replacing Rethermalizer Components...

  • Page 5: Service Procedures

    CHAPTER 1: SERVICE PROCEDURES 1.1 Functional Description FGP55 Series gas rethermalizers contain a welded stainless steel cookpot that is heated by gas flames diffused evenly through tubes built into the cookpot. Flames originate from orifices in a burner manifold positioned beneath the burners. The burners are positioned in the tube openings, at the front of the cookpot.
  • Page 6 (setpoints). The temperatures are programmed by means of a keypad on the face of the computer. All FGP55 Series gas rethermalizers are equipped with a high-limit thermostat. In the event that the rethermalizer fails to properly control the water temperature, the high-limit thermostat prevents the rethermalizer from overheating.

  • Page 7: Cleaning The Gas Valve Vent Tube (If Applicable)

    FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.2 Accessing Rethermalizers for Servicing DANGER Moving a rethermalizer filled with water may cause spilling or splattering of the hot liquid. Follow the draining instructions included with the rethermalizer before attempting to relocate a rethermalizer for servicing.

  • Page 8: Adjusting The Pilot Flame

    FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES Adjusting Burner Manifold Gas Pressure (cont.) 3. Insert the fitting for a gas pressure-measuring device into the pressure tap hole. 4. Place the gas valve in the "ON" position then place the rethermalizer power switch in the "ON"...

  • Page 9: Replacing Rethermalizer Components

    FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.6 Replacing Rethermalizer Components 1.6.1 Replacing the Computer or Solid State Relays 1. Disconnect the rethermalizer from the electrical supply. 2. Unscrew the two computer panel screws. The computer panel is hinged at the bottom and will swing open from the top.
  • Page 10 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.6.2 Replacing the Temperature Probe 1. Disconnect the rethermalizer from the electrical supply. 2. Drain the water from the cookpot. Allow the cookpot to cool completely before proceeding. 3. Remove the rethermalizer door for easier access to the temperature probe.
  • Page 11 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.6.2 Replacing the Temperature Probe (cont.) 6. Loosen unscrew completely compression nut, then the pass-through nut from the cookpot. Proceed to the next step before removing probe from cookpot. Note: The temperature probe can be...
  • Page 12 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.6.3 Replacing the High-Limit Thermostat 1. Turn rethermalizer off and drain water from the cookpot. Allow the cookpot to cool completely before proceeding. 2. Perform steps 1-4 in Section 1.6.1, Replacing the Computer.
  • Page 13 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.6.3 Replacing the High-Limit Thermostat (cont.) 6. Remove high-limit mounting bracket and high-limit spring inside cookpot. Retain mounting hardware for installation of new high-limit. Remove high-limit mounting hardware. Retain mounting hardware for installation of new high- limit.
  • Page 14 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.6.3 Replacing the High-Limit Thermostat (cont.) 8. Mark and disconnect wires at the high-limit in the component box. Mark and disconnect high-limit wiring (arrows). (Reconnect wires to the same terminals on the replacement high-limit.)
  • Page 15 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.6.4 Replacing Float Switches 1. Disconnect the rethermalizer from the electrical power supply. 2. Drain the water from the cookpot. Allow the cookpot to cool completely before proceeding. 3. Unplug the float switch connector.
  • Page 16 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.6.6 Replacing the Pilot Assembly 1. Remove the pilot tubing from the bottom of the pilot assembly. 2. If the pilot is an electronic ignition pilot, disconnect the ignition cable and the sense wire.
  • Page 17 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.6.7 Replacing the Cookpot (cont.) 7. Locate all screws securing back panels. Screw location/orientation will vary according to rethermalizer model. Typical back-panel screw locations. 8. Remove back panels on rethermalizer. Retain screws for re-assembly.
  • Page 18 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.6.7 Replacing the Cookpot (cont.) 10. Remove screws securing flue-cap braces to cookpot (a nut-driver with extension long screwdriver is required). Use care not to drop the screws into the flues. If this happens, the screws can be retrieved when the flue is removed (Step 12).
  • Page 19 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.6.7 Replacing the Cookpot (cont.) 12. Remove four bolts securing flue to the cookpot being removed. Remove the flue by sliding back and away until clear of cookpot. Retrieve any screws dropped into the flue during removal of the flue cap to cookpot bracket.
  • Page 20 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.6.7 Replacing the Cookpot (cont.) Each of the burners is unique in the flame-transfer hole configuration and must be reinstalled correctly: Left burners (L): Flame transfer hole is on the right side of the burner head.
  • Page 21 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.6.7 Replacing the Cookpot (cont.) 15. Remove screw(s) securing the electronic standing pilot bracket to the cookpot bracket. Reposition ignitor assembly down and away from cookpot. Use care not to bend, kink or damage the...
  • Page 22 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.6.7 Replacing the Cookpot (cont.) 21. Remove bolts from brackets securing burner manifold cookpot. Leave the manifold in place. Removing bolts (arrows) from burner manifold support brackets (both sides). Leave the burner manifold in place after removing bolts.
  • Page 23 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.6.8 Annotated Cookpot Bottom 1-19...

  • Page 24: Troubleshooting And Problem Isolation

    FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.7 Troubleshooting and Problem Isolation This section is intended to provide technicians with a general knowledge of the broad problem categories associated with this equipment, and the probable causes of each. With this knowledge, the technician should be able to isolate and correct any problem encountered.
  • Page 25 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.7.1 Ignition Failures (cont.) Problems Related to the Electronic Circuits If gas and electrical power are supplied to the rethermalizer, the next most likely cause of ignition failure is a problem in the 24 VAC circuit. First verify that the float switch valve is fully closed and not sticking.
  • Page 26 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.7.2 Improper Burner Functioning (cont.) If popping occurs only during peak operating hours, the problem may be incorrect or fluctuating gas pressure. Verify that the incoming gas pressure (pressure to the gas valve) is in accordance with the appropriate CE or Non-CE requirements listed in the Installation and Operation manual that came with the rethermalizer, and that the pressure remains constant throughout all hours of usage.
  • Page 27 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES Burners lighting on the left side only may be caused by a trailing pilot problem or improper burner manifold pressure. Fluctuating flame intensity is normally caused by either improper or fluctuating incoming gas pressure, but may also be the result of variations in the kitchen atmosphere.
  • Page 28 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.7.4 Computer-Related Problems Common Computer Complaints Most problems concerning computers have to do with programming them. There are four common complaints. The complaints, their causes, and corrective actions are: 1. Rethermalizer constantly displays "...
  • Page 29 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.7.5 Leakage Cookpot leaks are almost always due to improperly sealed high-limit, temperature probe, float switches and drain fittings. When installed or replaced, each of these components must be sealed with Loctite PST567 sealant or equivalent to prevent leakage. In very rare cases, a leak may develop along one of the welded edges of the cookpot, or where the tube is welded to the cookpot.

  • Page 30: Troubleshooting Guides

    FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES Troubleshooting Guides The following troubleshooting guides are intended to assist service technicians in quickly isolating the probable causes of equipment malfunctions by following a logical, step-by-step process. 1.8.1 General Troubleshooting PROBLEM PROBABLE CAUSES CORRECTIVE ACTION A.
  • Page 31 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.8.1 General Troubleshooting (cont.) PROBLEM PROBABLE CAUSES CORRECTIVE ACTION A. Press the ON/OFF switch off. Clean float switch and make sure that the float switch is not bent and that the A. Float switch stuck or defective.
  • Page 32 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.8.1 General Troubleshooting (cont.) PROBLEM PROBABLE CAUSES CORRECTIVE ACTION A. Water solenoid defective. A. Replace the defective solenoid valve. B. Press the ON/OFF switch off. Clean float switch and make sure that the float switch is not bent and that the float moves freely up and down.

  • Page 33: Probe Resistance Chart

    FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES Probe resistance Chart Probe Resistance Chart For use with rethermallizers manufactured with Minco Thermistor probes only. OHMS OHMS OHMS OHMS OHMS 1059 1204 1350 1493 1634 1070 1216 1361 1503 1644 1080...

  • Page 34: Wiring Diagrams

    FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.10 Wiring Diagrams Note: The diagrams in this section depict wiring as of the date of manual publication. It may not reflect design changes made to the equipment after publication. Refer to the wiring diagram affixed to the unit when actually troubleshooting this equipment.
  • Page 35 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.10.2 Wiring Diagram FGP255 w/ Electronic Standing Pilot without Interface Board 1-31...
  • Page 36 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.10.3 Wiring Diagram/ Without Interface Board (Without Electronic Ignition) 1-32...
  • Page 37 FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1: SERVICE PROCEDURES 1.10.4 FGP55 Wiring Diagram with Water Board (Old Style) Simplified 1-33...

  • Page 38: Parts List

    FGP55 SERIES GAS RETHERMALIZERS CHAPTER 2: PARTS LIST 2.1 FGP55 Primary Components...
  • Page 39 FGP55 SERIES RETHERMALIZERS CHAPTER 2: PARTS LIST 2.1 FGP55 Primary Components (cont.) ITEM PART # COMPONENT 823-3817SP Cookpot- W/A- FGP55 810-2034 Manifold, Gas 810-2048 Orifice, Natural Gas (G20/25) #39 (2.53 mm) 810-2060 Orifice, Natural Gas (G20/25) #42 (2.40 mm) 810-2059 Orifice, LP Gas (G30/31) #53 (1.51 mm)
  • Page 40 FGP55 SERIES RETHERMALIZERS CHAPTER 2: PARTS LIST 2.1 FGP55 Primary Components (cont.) ITEM PART # COMPONENT 803-0325 Insert, Master Rack 803-0324 Master Rack 9⅛” x 13.00” 106-2366SP Cover Assembly, includes item 29 826-1117 Caster, 5-inch w/o Brake Kit – includes washers and screws 826-1118 Caster, 5-inch with Brake Kit –...

  • Page 41: Components And Controllers

    FGP55 SERIES RETHERMALIZERS CHAPTER 2: PARTS LIST Components and Controllers Components are applicable to all FGP55 rethermalizers covered in this manual unless otherwise noted.
  • Page 42 FGP55 SERIES RETHERMALIZERS CHAPTER 2: PARTS LIST 2.2 Components and Controllers ITEM PART # COMPONENT 826-2117 Spark Module (Domestic and CE) 106-3553SP Cable, Ignition with Rajah Connector 210-3638 Panel, Control- Computer FGP55 106-3938 Computer, Assembly FGP55 includes item 4 823-3820...

  • Page 43: Float Switch Assemblies

    FGP55 SERIES RETHERMALIZERS CHAPTER 2: PARTS LIST 2.3 Float Switch Assemblies ITEM PART # COMPONENT 106-2345SP Switch, Float – High Level Assembly 807-3793 Switch, High Level 813-0805 Coupling, ⅛-inch NPT SS 813-0806 Nipple, ⅛-inch NPT x 1 ½ SS 813-0807 Bushing, ¼-inch NPT x ⅛-inch NPT SS...

  • Page 44: Control Boxes

    FGP55 SERIES RETHERMALIZERS CHAPTER 2: PARTS LIST 2.4 Control Boxes 2.4.1 Component and Spark Module Boxes without Waterboard For spark module, see Components and Controllers section 2.2. ITEM PART # COMPONENT 106-2358 Wireway Assembly, Component RG55 824-0967 Wireway Weldment, FGP55 Control Panel...
  • Page 45 FGP55 SERIES RETHERMALIZERS CHAPTER 2: PARTS LIST 2.4.2 Spark Module Control Box with PCB Waterboard ITEM PART # COMPONENT 806-9298 Control Box Assembly, Rethermalizer 900-5223 Cover, Control Box 900-8419 Front, Control Box CKE (use 900-8325 for Boston Market) 806-8007 Assembly, Component Box...

  • Page 46: Incoming Water Plumbing

    FGP55 SERIES RETHERMALIZERS CHAPTER 2: PARTS LIST 2.5 Incoming Water Plumbing ITEM PART # COMPONENT 813-0772 Nipple, ⅜-inch x CLS SS 813-0773 Elbow, ⅜-inch x 90° SS 813-0815 Nipple, ⅜-inch x 2-inch SS 810-2419 Valve, Check ⅜-inch NPT 813-0807 Bushing, ¼-inch NPT x ⅛-inch NPT SS 813-0806 Nipple, ⅛-inch NPT x 1½-inch SS...

  • Page 47: Drain And Associated Parts

    FGP55 SERIES RETHERMALIZERS CHAPTER 2: PARTS LIST 2.6 Drain and Associated Parts ITEM PART # COMPONENT 810-1825 Valve, 1¼-inch x 1¼-inch Drain SS 813-0801 Nipple, 1¼-inch NPT x CLS SS 823-5695 Handle, Drain Extension FGP55 816-0631 Sleeve, Drain Valve Handle - Red...

  • Page 48: Gas Plumbing

    FGP55 SERIES RETHERMALIZERS CHAPTER 2: PARTS LIST 2.7 Gas Plumbing ITEM PART # COMPONENT 810-2034 Gas Manifold 813-0174 Union, ¾-inch NPT 150# BM 813-0168 Elbow, Street ¾-inch x 90° BM 813-0259 Nipple, ¾-inch NPT x 6.00-inch BM 813-0066 Elbow, ¾-inch x 90° BM 813-0254 Nipple, ¾-inch NPT x 3.00-inch BM...

  • Page 49: Fasteners

    FGP55 SERIES RETHERMALIZERS CHAPTER 2: PARTS LIST Fasteners ITEM PART # COMPONENT 809-0428 Bolt, ¼-inch – 20 x ½-inch Hex Head ZP Tap 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...
  • Page 50 Dean, 8700 Line Avenue, PO Box 51000, Shreveport, Louisiana 71135-1000 Shipping Address: 8700 Line Avenue, Shreveport, Louisiana 71106 TEL 1-318-865-1711 FAX (Parts) 1-310-327-3343 FAX (Tech Support) 1-318-219-7135 819-6250 SERVICE HOTLINE PRINTED IN THE UNITED STATES OCTOBER 2006 1-800-551-8633...

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