Frymaster FilterQuick FQG30 Service Manual
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Frymaster FilterQuick FQG30 Service Manual

Gas fryer
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FilterQuick
Gas Fryer
Service Manual
This manual is updated as new information and models are released. Visit our website for the latest manual.
FOR YOUR SAFETY
Do Not Store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
*8197109*
Part Number: FRY_SM_8197109 12/2016
 
Original Instructions
™
FQG30
 

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Summary of Contents for Frymaster FilterQuick FQG30

  • Page 1 ™ FilterQuick FQG30 Gas Fryer Service Manual This manual is updated as new information and models are released. Visit our website for the latest manual. FOR YOUR SAFETY Do Not Store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
  • Page 2 RECEIVED FROM AN UNAUTHORIZED SERVICER. NOTICE This appliance is intended for professional use only and is to be operated by qualified personnel only. A Frymaster Factory Authorized Servicer (FAS) or other qualified professional should perform installation, maintenance, and repairs. Installation, maintenance, or repairs by unqualified personnel may void the manufacturer’s warranty. See Chapter 1 of this manual for definitions of qualified personnel.
  • Page 3 CAUTION No warranty is provided for any Frymaster fryer used in a mobile or marine installation or concession. Warranty protection is only offered for fryers installed in accordance with the procedures described in this manual. Mobile, marine or concession conditions of this fryer should be avoided to ensure optimum performance.

  • Page 4: Table Of Contents

    ™ FILTERQUICK FQG30 SERIES GAS FRYERS SERVICE MANUAL TABLE OF CONTENTS CHAPTER 1: Service Procedures Functional Description ................................1-1 The Electronic Ignition System ............................. 1-1 Interface Board ..................................1-2 Thermostats ....................................1-4 Accessing Fryers for Servicing .............................. 1-4 Cleaning the Gas Valve Vent Tube ............................1-4 Checking the Burner Manifold Gas Pressure ........................
  • Page 5 1.17.3 Replacing an AIF (Automatic Intermittent Filtration) Board............... 1-42 1.17.4 Replacing a Rotary Actuator .......................... 1-42 1.17.5 Oil Level Sensor ..............................1-42 1.17.5.1 Oil Level Sensor Troubleshooting ..................1-43 1.17.5.2 Oil Level Sensor Diagram ......................1-44 ™ 1.18 FilterQuick Controller Service Procedures ........................1-44 ™...

  • Page 6: Chapter 1: Service Procedures

    ™ FILTERQUICK FQG30 SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES Functional Description FilterQuick™ FQG30 Series gas fryers contain a welded stainless steel frypot that is directly heated by a high efficiency infrared burner system, requiring approximately 43% less energy than conventional burners to cook the same volume.

  • Page 7: Interface Board

    The blower is on during the heating cycle. The blower also turns on if the oil temperature exceeds 2°F above setpoint and during filtration to help cool the frypot to minimize caramelization of the oil on the frypot interior. Interface Board All fryers in this series have an interface board located in the component box behind the control panel.

  • Page 9: Thermostats

    FREQUENTLY USED TEST POINTS FOR INTERFACE BOARD 106-6706 Meter Test Setting Pins Results 12VAC Power to Controller 50VAC Scale 1 and 3 on J3 or J2 12-18 24VAC Power to Right Module 50VAC Scale 8 on J3 and GROUND 22-28 24VAC Power to Left Module (if present) 50VAC Scale 8 on J1 and GROUND...

  • Page 10: Checking The Burner Manifold Gas Pressure

    Checking the Burner Manifold Gas Pressure 1. On non-CE fryers only ensure that the gas valve knob is in the OFF position. Honeywell 2. Remove the pressure tap plug from the gas valve assembly. Pressure Tap Plug Typical Non-CE Typical CE Valve Valve Assembly Assembly 3.

  • Page 11: Measuring Flame Current

    6. To adjust the burner gas pressure, remove the cap from the gas valve regulator and adjust to the correct pressure. Non-CE Valve Valve GAS VALVE REGULATOR CAP 7. Place the fryer power switch (and the gas valve in non-CE fryers) in the OFF position. Remove the fitting from the pressure tap hole and reinstall the pressure tap plug.

  • Page 12: Replacing The Interface Board

    Ground Wire Terminal Ground Wire Terminal 20-Pin Connector Drain Switch and LED Communication Wires Locator Wire 5. Install the replacement controller. Reinstall the control panel assembly by reversing steps 1 thru 5. ™ 6. Setup the controller following the instructions on page 1-3 in the FilterQuick Controller Operation manual.

  • Page 13: Replacing An Ignition Module

    5. Reverse the procedure to install the replacement board, being sure that the spacers behind the board are in place and the controller locator wire is attached to a stud. 1.9.4 Replacing an Ignition Module 1. Disconnect the fryer from the electrical supply. 2.
  • Page 14 Blower assembly mounting nuts Wiring connection 2. Remove the blower motor shield and separate the blower motor from the housing as shown in the illustration below. Remove these screws to remove the shield from the blower assembly. Remove these nuts to separate the blower motor from the housing.

  • Page 15: Adjusting The Air/Gas Mixture

    5. Reinstall the blower assembly in the fryer and reconnect the wiring disconnected in Step 1. 6. Light the fryer in accordance with the procedure described in Chapter 3, Section 3.1.2 of the FilterQuick™ FQG30 Series Gas Fryer Installation and Operation Manual (P/N 819-6286). 7.

  • Page 16: Replacing A Burner Assembly

    C. Uncouple the pipe union and remove the gas valve and associated piping from the unit. D. Remove the fittings and associated piping from the failed valve and install them on the replacement valve ® using Loctite PST56765 or equivalent pipe thread sealant. ®...

  • Page 17: Replacing The Frypot

    a. If the welds in the lower rail are cracked or burned out, the frypot must be replaced. Refer to Section 1.9.11 for procedure. b. If the welds in the upper rail are cracked or burned out, the upper rail must be replaced. Refer to Section 1.9.12 for procedure.

  • Page 18: Replacing Frypot Insulation And/Or Upper Burner Rails

    2. Remove the filter pan from the unit and drain one frypot at a time into a Shortening Disposal Unit (SDU) or other appropriate metal container using the drain function on the MIB board (see section 1.14 on page 29). DANGER DO NOT attempt to drain more than one full frypot or two split frypots into the SDU at...
  • Page 19 NOTE: Replacing the burner rails requires completely tearing down the frypot and installing new frypot insulation. Refer to the frypot exploded view below for component identification. 1. Remove the frypot per Section 1.9.11. 2. Remove the burner assemblies (1). 3. Remove insulation retainers and blanket insulation (2). 4.
  • Page 20 16. Place the upper inner combustion chamber insulation and insulation retainers (3) on the top two studs on each side of the front of the frypot and secure with ¼”-20 washer-nuts. It is normal for the retainers to slice off the overhanging insulation. 17.

  • Page 21: Troubleshooting And Problem Isolation

    Re-assembling A Frypot (Full-Vat Illustrated) 1.10 Troubleshooting and Problem Isolation Because it is not feasible to attempt to include in this manual every conceivable problem or trouble condition that might be encountered, 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.

  • Page 22: Improper Burner Function

    1. Gas and/or electrical power supplies 2. Electronic circuits 3. Gas valve. PROBLEMS RELATED TO THE GAS AND/OR ELECTRICAL POWER SUPPLIES The main indicators of this are that an entire battery of fryers fails to light and/or there are no indicator lights illuminated on the fryer experiencing heating failure.

  • Page 23: Improper Temperature Control

    If popping is consistent during all hours of operation, the most likely cause is an insufficient air supply. Check for “negative pressure” conditions in the kitchen area. If air is flowing into the kitchen area, this indicates that more air is being exhausted than is being replenished and the burners may be starved for air.

  • Page 24: Controller Malfunctions

    Initiation of the melt cycle with FilterQuick™ controllers is automatic. Problems may originate from the controller itself, the temperature probe, or a malfunctioning heat relay on the interface board. FAILURE TO CONTROL AT SETPOINT Problems in this category may be caused by the temperature probe, the interface board, or the controller. 1.10.4 Controller Malfunctions RECOVERY TIME Recovery time –...

  • Page 25: Leakage

     Turning the pump gears backwards will release a hard particle and allow its removal.  Turning the pump gears forward will push softer objects and solid shortening through the pump and allow free movement of the gears Filter paper/pads that are installed incorrectly will also allow food particles and sediment to pass through and clog the suction tube recess on the bottom of the filter pan or the suction tube, itself.
  • Page 26 a. Check continuity of high-limit thermostat. If it is zero, problem is in wiring. 2. If 24 VAC is present across the gas valve main coil (MV terminals), the 24 VAC circuit is working and the problem may be with the gas valve. Be sure to check both valves on dual vat units. 1-21...

  • Page 27: Troubleshooting The Gas Valve

    1.11.2 Troubleshooting the Gas Valve Prior to checking for problems associated with the gas valve, ensure that the unit is calling for heat. Also, for non-CE units, verify that the gas valve is in the ON position. The following processes will assist you in troubleshooting the gas valve and ruling it out as a probable cause: ...

  • Page 28: Troubleshooting The Temperature Probe

     If 24 VAC is present across gas valve main coil, check the incoming gas pressure and compare to the tables on page 2-4 of the Installation and Operation manual. 1. If incoming gas pressure is not correct, the probable cause is a problem with the gas supply to fryer. 2.

  • Page 29: Basket Lift Service Procedures

    1.12 Basket Lift Service Procedures ™ FQG30 series gas fryers may be equipped with automatic basket lifts. Basket lifts always come in pairs, although each operates independently. A modular basket lift (illustrated on the following page) is a self-contained sub-assembly consisting of a pair of toothed rods, which support removable basket lift arms, a pair of reversible-drive gear motors, and four microswitches.
  • Page 30 With the modular basket lift, another possible cause of binding is improper positioning of the motor, which prevents the gear from correctly engaging the teeth in the rod. To correct the problem, loosen the screws that hold the motor in place and move it forward or backward until the rod has just enough slack to be rotated slightly.

  • Page 31: Probe Resistance Chart

    1.13 Probe Resistance Chart Probe Resistance Chart For use with FilterQuick™ Series fryers manufactured with Minco Thermistor probes only. OHMS OHMS OHMS OHMS OHMS 1059 1204 1350 1493 1634 1070 1216 1361 1503 1644 1080 1226 1371 1514 1654 1091 1237 1381 1524...
  • Page 32 Problem Probable Causes Corrective Action A. Ensure JIB has oil. B. Check to see that fryer is heating. Fryer temperature must be at setpoint. Check probe resistance. If probe is bad, replace the probe. C. Ensure that the oil in the JIB is above 70°F (21°C).
  • Page 33 1.14.2 ATO (Automatic Top-Off) Board Pin Positions and Harnesses Wire Connector From/To Harness # Function Voltage Color Bulk Fresh Oil Solenoid 24VAC Black 24VAC Ret Top Off Pump Relay 24VAC Black 24VAC Ret 16VDC JIB Reset Switch JIB Low Reset Black 8074671 Bulk Fresh Oil Solenoid...

  • Page 34: Replacing The Ato Pump Or Solenoid

    1.14.3 Replacing the ATO Board, ATO Pump Relay or Transformer Disconnect the fryer from the electrical power supply. Locate the ATO box (see Figure 1 on page 1-26), behind the JIB (Jug In Box). Remove the cover to expose the transformers and relay (see Figure 2). Mark and unplug any wires or harnesses.

  • Page 35: Manually Draining, Refilling Or Filtering Using The Mib Board

    Buttons and LED’s Manual – This button is used to toggle between auto and manual filtration mode. A corresponding LED is lit when in Manual mode. When pressed, a message will be sent to all vats, indicating the mode has changed. The following buttons are inoperable in auto mode: Select - This button is used to scroll through available vats, choosing one to be manually filtered.

  • Page 36: Mib (Manual Interface Board) Troubleshooting

    1.15.2 MIB (Manual Interface Board) Troubleshooting Problem Probable Causes Corrective Action A. Ensure filter pan is fully inserted into fryer. If the MIB board displays a “P” the pan is A. Filter pan out of position. not fully engaged into the pan switch. B.
  • Page 37 Problem Probable Causes Corrective Action A. Ensure the CAN bus system is terminated at the FilterQuick™ BOTH ENDS controller connector J6 and on the ATO board connector J10) with a resistor equipped 6-pin connector. B. With controller OFF, press temperature button and ensure the AIF version appears.

  • Page 38: Mib (Manual Interface Board) Pin Positions And Harnesses

    1.15.3 MIB (Manual Interface Board) Pin Positions and Harnesses Connector From/To Harness # Pin # Function Voltage Wire Color Ground Black CAN Lo FilterQuick™ CAN Hi White Controller/ 8074546 Ground Black CAN Lo CAN Hi White AIF J5 8074850 5VDC+ 5VDC Black 24VDC...

  • Page 39: Mib (Manual Interface Board) Display Characters

    1.15.4 MIB (Manual Interface Board) Display Characters A – Auto Mode – Auto Filtration enabled. E – Drain or return valve is not in desired state. The display will alternate between E and the corresponding vat number. Ensure the actuator is plugged in and an error does not exist. –...

  • Page 40: Control Power Reset Switch

    1.15.6 Control Power Reset Switch The control power reset switch, is a momentary rocker switch located below the left control box (see Figures 14), that resets all power to all the controllers and boards in the fryer. It is necessary to reset all power after replacing any controller or board.

  • Page 41: Bulk Wiring

    1.16.2 Bulk Wiring 1-36...

  • Page 42: Bulk Oil Test Quick Reference

    1.16.3 Frymaster FilterQuick™ Fryer and Bulk Oil System Plumbing Schematic Bulk Oil Company Fryer Components Return Components Valves Frypots Check Valve Bulk Oil Manifold Check Valve New Oil Pump Top-0ff New Oil Solenoid Drain Pump Tank Valve Ball Valves Bypass...
  • Page 43 22. Close dispose valve ensuring the handle is pushed completely towards the fryer. 23. “Fill Vat From Bulk? Yes/No” is displayed. 24. Press “Yes”. 25. “Press and Hold Yes Arrow to Fill” alternating with “Yes” is displayed. 26. Hold down “Yes” to fill pot to desired level. 27.

  • Page 44: Aif (Automatic Intermittent Filtration) Service Procedures

    The system also checks these conditions. The following must be met before jug fill is allowed.  Solenoid closed  Orange fill button pressed longer than 3 sec.  Waste valve closed  Filter Now? Yes/No, Confirm Yes/No, or Skim Vat cannot be displayed ...
  • Page 45 Problem Probable Causes Corrective Action Check power on the connector of the problem actuator while trying to manually open or close an actuator. Pins 1 (Black) and 4 (White) should read +24VDC when the actuator is opening. Pins 2 (Red) and 4 (White) should measure -24VDC when the actuator is closing).
  • Page 46 1.17.2 AIF (Auto Intermittent Filtration) Actuator Board Pin Positions and Harnesses Wire Connector From/To Harness PN Function Voltage Color Ret + (Open) 24VDC Black Ret – (Closed) 24VDC FV Return Ret Position Blue Ground White Ground FV AIF RTD FV - Temp White Ground DV AIF RTD...

  • Page 47: Replacing An Aif (Automatic Intermittent Filtration) Board

    1.17.3 Replacing an AIF (Automatic Intermittent Filtration) Board Disconnect the fryer from the electrical power supply. Locate the AIF board to be replaced under a frypot. Mark and unplug the harnesses. The AIF board assembly is held in place with one screw (see Figure 16). Remove the screw and the assembly drops down (see Figure 17) and the tab slides out of the bracket attached to the frypot (see Figure 18).

  • Page 48: Oil Level Sensor Troubleshooting

    If oil is surrounding the heater, the oil will prevent the heater from ever reaching its setpoint. Once oil is removed during filtration the heater reaches setpoint and cycles a thermostat every four seconds. Since the cycle is only four seconds, the seven second delay is not made and the gas valve won’t open.

  • Page 49: Oil Level Sensor Diagram

    1.17.5.2 Oil Level Sensor Diagram NOTE: See page 1-70 for alternate time delay relays. Black (Line Voltage in from J3 Thermocouple pin 11 to T1 thru relay) Fixed Setpoint Heater 120V (220-240V Intl) (350 ohms US) Temp. Control (1325 ohms Intl) White (To T2 Terminal Block) 120V (220-...
  • Page 50 Problem Probable Causes Corrective Action FILTER and CLEAN Ensure fryer is at setpoint before starting these Temperature too low. AND FILTER won’t functions. start. A. Wait until the previous filtration cycle ends to start another filtration cycle or until the MIB board has reset.
  • Page 51 Problem Probable Causes Corrective Action This display is normal when the fryer is first turned on while in the melt cycle mode. To bypass the melt cycle press the “COOL” Controller displays vat button. controller displays Frypot temperature is below 180°F (82°C). EXIT temperature alternating MELT? alternating with YES NO.

  • Page 52: Filterquick

    Problem Probable Causes Corrective Action A. An error has occurred due to carbon A. If answering yes directs to clean oil sensor, buildup on oil level sensor. Normal clean oil level sensor with a scratch pad and after some filter menu functions retry.

  • Page 53: Service Required Errors

     Reset BADCRC Message - Disconnect board locator plug (J3). Reinsert plug. Enter 9988. Controller display switches to off. Remove and then restore power to the controller using the 20-pin plug. Replace the controller. PASSWORDS  Product Setup Mode: Press and hold the  button until Main Menu changing to Product setup is displayed.
  • Page 54 CODE ERROR MESSAGE EXPLANATION unknown. ERROR AIF BOARD MIB detects AIF missing; AIF board failure Cooking controller detects MIB connections lost; Check software version on each controller. ERROR MIB BOARD versions are missing, check CAN connections between each controller; MIB board failure ERROR AIF PROBE AIF RTD reading out of range ERROR ATO PROBE...

  • Page 55: Filterquick ™ Filter Error Flowchart

    ™ 1.18.5 FilterQuick Filter Error Flowchart NORMAL OPERATION RESUMES MESSAGE DISPLAYED ANSWERING NO 3X Call an SIXTH Authorized CONSECUTIVE Repair FILTER ERROR Technician Fryer returns Fryer to cook mode returns to for 4 minutes cook mode or 15 minutes for 15 if paper Change filter minutes.

  • Page 56: Clogged Drain/Failed Oil Sensor Flowchart

    1.18.6 Clogged Drain/Failed Oil Sensor Error Flowchart 1-51...

  • Page 57: Menu Trees

    1.18.7 Menu Trees ™ 1.18.7.1 FilterQuick Controller Setup Menu Tree 1-52...

  • Page 58: Filterquick Filter And Info Mode Menu Tree

    ™ 1.18.7.2 FilterQuick Filter and Info Mode Menu Tree 1-53...

  • Page 59: Filterquick Board Pin Positions And Harnesses

    ™ 1.18.8 FilterQuick Controller Board Pin Positions and Harnesses Connector From/To Harness PN Function Voltage Wire Color SD Card 12VAC In 12VAC Ground 12VAC Return In 12VAC FV Heat Demand V Relay 12VDC DV Heat Demand R/H B/L 12VDC Analog Ground L/H B/L 12VDC 8075165...

  • Page 60: Oqs (Oil Quality Sensor) Troubleshooting

    1.18.9 OQS (Oil Quality Sensor) Troubleshooting Problem Probable Causes Corrective Action Check the following items A-E and perform another OQS filter. A. Ensure the vat is at setpoint temperature. B. Inspect the pre-screen filter and ensure it is screwed in tightly. C.

  • Page 61: Loading And Updating Software Procedures

    1.19 Loading and Updating Software Procedures Updating the software takes approximately 30 minutes. The software only needs to be loaded in ONE controller and it will update all the controllers and boards in the system. Typically this is done on the far left controller. To update the software, follow these steps carefully: 1.

  • Page 62: Principal Wiring Connections

    1.20 Principal Wiring Connections 1-57...

  • Page 63: Wiring Diagrams

    1.21 Wiring Diagrams 1.21.1 Main FQG 230/430 120V/CE/Export 1-58...

  • Page 64: Main Fqg 230/430 Australia

    1.21.2 Main FQG 230/430 Australia 1-59...

  • Page 65: Main Fqg 230/430 120V/Ce/Export With Solid Shortening

    1.21.3 Main FQG 230/430 120V/CE/Export with Solid Shortening 1-60...

  • Page 66: Main Fqg 230/430 Australia With Solid Shortening

    1.21.4 Main FQG 230/430 Australia with Solid Shortening 1-61...

  • Page 67: Main Fqg 330/530 120V/Ce/Export

    1.21.5 Main FQG 330/530 120V/CE/Export 1-62...

  • Page 68: Main Fqg 330/530 Australia

    1.21.6 Main FQG 330/530 Australia 1-63...

  • Page 69: Main Fqg 330/530 120V/Ce/Export With Solid Shortening

    1.21.7 Main FQG 330/530 120V/CE/Export with Solid Shortening 1-64...

  • Page 70: Main Fqg 330/530 Australia With Solid Shortening

    1.21.8 Main FQG 330/530 Australia with Solid Shortening 1-65...

  • Page 71: Transformer/Filter Box 430/530

    1.21.9 Transformer / Filter Box 430/530 1-66...

  • Page 72: Simplified Wiring Diagrams

    1.22 Simplified Wiring Diagrams 1.22.1 FilterQuick™ FQG30 Series Simplified Wiring with Push Pull Handles 1-67...
  • Page 73 1.22.2 FilterQuick™ FQG30 Series Simplified Wiring with Push Buttons 1-68...

  • Page 74: Filterquick™ Fqg30 Series Data Network Flowchart

    1.22.3 FilterQuick™ FQG30 Series Data Network Flowchart 1-69...

  • Page 75: Alternate Time Delay Relay Wiring Diagrams

    1.23 Alternate 7 sec. Time Delay Relay Wiring Diagrams PN 807-4934 220V-250V (Intl. Units), PN 807-4812 120V (US, Canada & Mexico) 1-70...

  • Page 76: Shortening Melting Unit Wiring Diagram

    1.24 Shortening Melting Unit Wiring Diagram 1-71...
  • Page 77 1.25 Modular Basket Lift Wiring Diagram 100-120V 1-72...
  • Page 78 1.26 Modular Basket Lift Wiring Diagram 208-250V 1-73...
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  • Page 80 FRYMASTER  8700 LINE AVENUE, SHREVEPORT, LA 71106‐6800    318‐865‐1711  844‐724‐CARE (2273)    800‐551‐8633  WWW.FRYMASTER.COM  EMAIL: FRYSERVICE@MTWFS.COM  *8197109* Every new piece of Manitowoc Foodservice equipment comes with KitchenCare™ and you choose the level of service that meets your operational needs from one restaurant to multiple locations. StarCare – Warranty & lifetime service, certified OEM parts, global parts inventory, performance audited ExtraCare –...

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