Frymaster Gas Rethermalizers FBRA18 Series Installation And Operation Manual
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Frymaster Gas Rethermalizers FBRA18 Series Installation And Operation Manual

Gas rethermalizers
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Frymaster, a member of the Commercial Food Equipment Service Association, recommends
using CFESA Certified Technicians.
819-5278
24-Hour Service Hotline 1-800-551-8633
May 2003

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  • Page 1 Frymaster, a member of the Commercial Food Equipment Service Association, recommends using CFESA Certified Technicians. 819-5278 24-Hour Service Hotline 1-800-551-8633 May 2003...
  • Page 2 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.

  • Page 4: Table Of Contents

    FBR18 & FBRA18 SERIES GAS RETHERMALIZERS CHAPTER 1: General Information Parts Ordering and Service Information ...1-1 Safety Information ...1-1 Equipment Description ...1-2 Installation, Operating, and Service Personnel ...1-2 Definitions...1-2 Shipping Damage Claim Procedure...1-3 CHAPTER 2: Installation Instructions General Installation Requirements...2-1 Caster/Leg Installation ...2-2 Pre-Connection Preparations ...2-2 Connecting to the Gas Supply...2-4...
  • Page 5 Temperature Probe ... 6-3 Water Level Sensors (FBRA18 Only)... 6-3 Accessing the Rethermalizer for Servicing ... 6-4 Cleaning the Gas Valve Vent Tube ... 6-4 Checking the Burner Manifold Gas Pressure ... 6-4 Measuring Flame Current... 6-4 Replacing Components... 6-5 6.6.1 Replacing the Controller or Controller Wiring Harness ...

  • Page 6: Chapter 1: General Information

    CHAPTER 1: GENERAL INFORMATION Parts Ordering and Service Information In order to assist you as quickly as possible, the Frymaster Factory Authorized Service Center (FASC) or Service Department representative requires certain information about your equipment. Most of this information is printed on a data plate affixed to the inside of the door.

  • Page 7: Equipment Description

    (457mm x 609mm) and holds 25 gallons (94.6 liters) of water. Installation, Operating, and Service Personnel Operating information for Frymaster equipment has been prepared for use by qualified and/or au- thorized personnel only, as defined in Section 1.5. All installation and service on Frymaster equipment must be performed by qualified, certified, licensed, and or/authorized installation or service personnel, as defined in Section 1.5.

  • Page 8: Qualified Service Personnel

    Frymaster equipment parts. A list of Frymaster Factory Authorized Service Centers (FASC) was included with the unit when it was shipped from the factory. Failure to use qualified service personnel will void the Frymaster Warranty on your equipment.

  • Page 9: Chapter 2: Installation Instructions

    General Installation Requirements PROPER INSTALLATION IS ESSENTIAL FOR EFFICIENT, TROUBLE-FREE OPERATION OF YOUR RETHERMALIZER. ANY UNAUTHORIZED ALTERATIONS MADE TO THIS EQUIPMENT WILL VOID Frymaster WARRANTY. Upon arrival, inspect the rethermalizer carefully for visible or concealed damage. (See Shipping Damage Claim Procedure in Chapter 1.) CLEARANCE AND VENTILATION This equipment must be installed with a 6”...

  • Page 10: Electrical Grounding Requirements

    Frymaster computers have been tested and found to comply with the limits for a Class A digi- tal device, pursuant to Part 15 of the FCC rules. While these devices are verified as Class A devices, they have been shown to meet the Class B limits.
  • Page 11 After the unit has been positioned in the area where it will be used, ensure the following has been accomplished before connecting the unit to the gas supply: 1. Adequate means must be provided to limit the movement of this equipment without depending upon the gas line connections.

  • Page 12: Connecting To The Gas Supply

    Connecting to the Gas Supply GAS CONNECTIONS AND PIPE SIZES The size of the gas supply pipe is very important. If the pipe is too small, the gas pressure at the burner manifold will be low. This will cause slow recovery and delayed ignition. The incoming gas supply line should be a minimum of 1½...

  • Page 13: Converting To Another Gas Type

    “Dry-firing” this equipment will cause damage to the cookpot. Always ensure that the cookpot is filled with water before firing your unit. 4. It is suggested that the burner manifold pressure be checked at this time by the local gas com- pany or an authorized service agent.

  • Page 14: Chapter 3: Operating Instructions

    The timers are equipped with an alarm to notify the operator that rethermalizing is complete. The prod- uct baskets have color-coded handles that correspond to the timers to eliminate confusion. FBR18/FBRA18 Digital Controller Frymaster Temperature or Setpoint Display Switch...

  • Page 15: Operating The Fbr18/Fbra18 Timers

    NOTE: The unit comes from the factory configured to display in degrees Fahrenheit. To toggle back and forth between Fahrenheit and Celsius, press the Celsius/Fahrenheit display switch. 2. The controller will automatically cycle the burners on and off seven times or until the tempera- ture in the cookpot reaches 160°F (71°C), whichever comes first.

  • Page 16: Boiling Out The Cookpot

    To ensure that the cookpot is free of any contamination resulting from its manufacture, shipping, and handling during installation, the cookpot must be boiled out before first use. 1. Close the drain valve and fill the cookpot with a solution of cold water and 1 cup of Frymaster FRYER ‘N’ GRIDDLE cleaner or detergent.

  • Page 17: Shutting The Rethermalizer Down

    6. Reprogram the setpoint to the appropriate temperature. Shutting the Rethermalizer Down 1. Turn the unit off by pressing the Power switch. 2. If shutting down at the end of the day, turn the gas valve to the OFF position (see illustration below), and drain and clean the cookpot.

  • Page 18: Chapter 4: Preventive Maintenance

    FBR18 & FBRA18 SERIES GAS RETHERMALIZERS CHAPTER 4: PREVENTIVE MAINTENANCE Daily Checks and Services Inspect Rethermalizer and Accessories for Damage Look for loose or frayed wires and cords, leaks, foreign material in cookpot or inside cabinet, and any other indications that the rethermalizer and accessories are not ready and safe for operation. Clean Cabinet Inside and Out Clean inside the cabinet with a dry, clean cloth.

  • Page 19: Semi-Annual Checks And Services

    2. Press the Temperature Display by the temperature probe. Press the Temperature Display point. The displayed water temperature should be within ±10°F (5°C) of the setpoint and the temperature shown on the thermometer or pyrometer should be within ± 5ºF (2ºC) of the displayed water temperature.

  • Page 20: Check Burner Manifold Pressure

    5. Reinstall tube and bend so that the opening is pointing downward. Check Burner Manifold Pressure Frymaster recommends that this task be performed by the local gas company or an authorized service technician only. 1. Ensure that the gas valve knob is in the OFF position.
  • Page 21 4. If necessary, adjust the burner gas pressure by removing the cap from the gas valve regulator and turning the regulator screw to obtain the correct pressure. When the correct pressure is obtained, reinstall the cap. 5. Place the controller power switch and the gas valve in the OFF position. Remove the fitting from the pressure tap hole and reinstall the pressure tap plug.

  • Page 22: Chapter 5: Operator Troubleshooting

    If you have doubts as to the proper action to take, do not hesitate to call the Frymaster Technical Service Department or your local Frymaster Factory Authorized Service Center for assistance.
  • Page 23 Troubleshooting Guides NOTE: This guide applies to FBRA18 units only. Controller is not functioning. Probable causes are failed 12V transformer, failed interface board, or failed controller. Probable causes are a failed interface board or failed/loose high-level water Call FASC. COOKPOT DID NOT FILL WHEN UNIT WAS TURNED ON.
  • Page 24 NOTE: This guide applies to FBRA18 units only. Problem resolved. Mineral content of water is insufficient for water sensor to detect it. Whenever cookpot is refilled, add 1/8 cup of salt. Remove the cover over the water sensors and thoroughly clean the sensors with a Scotchbrite or similar pad.
  • Page 25 WATER NOT HEATING. AUTOFILL (IF INSTALLED) WORKED PROPERLY. Press the Temperature Check button twice to display setpoint. Has the correct setpoint been programmed? Did burners light? Insert a good grade thermometer into Did water reach setpoint temperature? the Temperature Check button once to Problem resolved.
  • Page 26 BURNERS DO NOT LIGHT. Verify that correct setpoint has been programmed, that main gas supply valve is open, and that equipment gas valve is set to ON. Press ON/OFF button. Did burners light? Use bottlebrush to clean low water sensor. If burners still do not light, remove the cover over the water sensors and thoroughly clean them with a Scotchbrite or similar nylon pad.

  • Page 27: Replacing The Controller Or Controller Wiring Harness

    Replacing the Controller or Controller Wiring Harness 1. Disconnect the rethermalizer from the electrical supply. 2. Remove the two screws in the upper corners of the control panel and swing the panel open from the top, allowing it to rest on its hinge tabs. 3.

  • Page 28: Chapter 6: Service Procedures

    FBR18 & FBRA18 SERIES GAS RETHERMALIZERS CHAPTER 6: SERVICE PROCEDURES Functional Description These rethermalizers contain a welded stainless steel cookpot that is directly heated by a high effi- ciency burner system requiring approximately 43% less energy than conventional burner systems to heat the same volume of water.

  • Page 29: Controller And Mechanical Timers

    guished), current to the ignition module is cut, preventing the main valve from opening, and the igni- tion module “locks out” until the power switch is turned off and then back on. A probe monitors the temperature in the cookpot. When the programmed setpoint temperature is reached, resistance in the probe causes the heat cycle circuitry in the controller to cut off current flow through the heat relay.

  • Page 30: Temperature Probe

    The relays in earlier design boards are soldered on and cannot be replaced. Later design boards fea- ture replaceable plug-in relays. In earlier designs boards, a heat relay (K2) switches 24VAC to the ignition and gas valve circuits when the controller heat logic circuit calls for heat. Simultaneously, a blower motor relay (K4) switches 120VAC to the blower motor.

  • Page 31: Accessing The Rethermalizer For Servicing

    the upper water level sensor causes the water relay (K2) to open. This cuts power to the water sole- noid valve, which closes, cutting off water flow into the cookpot. Accessing the Rethermalizer for Servicing Moving a rethermalizer filled with hot water may cause spilling or splattering of the hot water.

  • Page 32: Replacing Components

    the unit exceeds that temperature, the burner will stay on until the setpoint is reached. Check the reading when the burner has been on continuously for at least one minute. Replacing Components 6.6.1 Replacing the Controller or Controller Wiring Harness Refer to Chapter 5, Section 5.3 for this procedure.

  • Page 33: Replacing An Ignition Module

    7. Remove the two upper screws securing the component box to the rethermalizer. Rotate the box forward and outward to expose the 12-pin connector on the rear of the interface board, and un- plug it from the board. 4. On FBRA18 models only, mark the water level sensor wires and disconnect them from terminals J1-1 (upper sensor) and J1-2 (lower sensor).

  • Page 34: Replacing The Combustion Air Blower

    5. Reconnect the ignitor wire, flame sensor wire, and gas enrichment tube. 6.6.6 Replacing the Combustion Air Blower Refer to Chapter 4, Section 4.4, Clean Combustion Air Blower, for instructions on removing and reinstalling the combustion air blower. 6.6.7 Replacing the Gas Valve 1.

  • Page 35: Replacing The Cookpot

    4. Remove the four screws from the blower stabilizing bracket attached to the blower assembly and to each burner. Remove the stabilizing bracket from the unit. 5. Remove the screw securing the blower support bracket to the cookpot assembly and lower the blower assembly out of the way.

  • Page 36: Ignition Failures

    knowledge of possible problems, and the probable causes of each. With this knowledge, the techni- cian should be able to isolate and correct any problem encountered. Problems that are likely to be encountered can be grouped into five broad categories: 1.

  • Page 37: Troubleshooting The Gas Valve

    tion failure situation may be encountered in which all components appear to be serviceable and the microamp reading is within specification, but the unit nevertheless goes into ignition failure during operation. The probable cause in this case is an intermittent failure of an ignition module. When the unit is opened up for troubleshooting, the module cools down enough to operate correctly, but when the unit is again closed up and placed back into service, the module heats up and fails.
  • Page 38 If popping is consistent during all hours of operation, the most likely cause is an insufficient air sup- ply. 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 39: Improper Temperature Control

    6.7.3 Improper Temperature Control Temperature control is a function of several interrelated components, each of which must operate correctly. The principle component is the temperature probe. Other components include the inter- face board, the water level sensors (on FBRA18 units), the controller, and the ignition module. Whatever the cause, the symptom is failure of the unit to attain or maintain setpoint temperature.

  • Page 40: Troubleshooting The Gas Valve

    6.8.1 Troubleshooting the Gas Valve Natual Gas Is incoming gas pressure 6-14" W.C. (1.49-3.49 kPa)? Is burner manifold gas pressure 3.5" W.C. (0.8 kPa)? Is gas valve vent tube obstructed? MAIN GAS SUPPLY VALVE VERIFIED TO BE OPEN AND EQUIPMENT GAS VALVE IN ON POSITION.

  • Page 41: Troubleshooting The 24 Vac Circuit In Fbr18 Units

    6.8.2 Troubleshooting the 24 VAC Circuit in FBR18 Units UNIT IS CONNECTED TO POWER SUPPLY, DRAIN VALVE IS FULLY CLOSED, CONTROLLER IS ON AND IS CALLING FOR HEAT (decimal appears between first two digits in controller display). Is 24VAC present on interface board J3 pin 9 (LED 5 (GV) lit)? Is LED 3 (24V) lit...
  • Page 42 THE 24 VAC CIRCUIT IN FBR18 UNITS TRANSFORMER J3 PIN 8 3 (24V) RELAY K2 ON EARLY DESIGN BOARDS RELAY K3 ON LATER DESIGN BOARDS 4 (PWR) RIGHT PWR TERMINAL J2 PIN 7 BLOWER CENTRIFUGAL SWITCH RIGHT IGNITION MODULE J2 PIN 5 V1S TERMINAL 2 (PWR) LEFT PWR TERMINAL...

  • Page 43: Troubleshooting The 24 Vac Circuit In Fbra18 Units

    6.8.3 Troubleshooting the 24 VAC Circuit in FBRA18 Units UNIT IS CONNECTED TO POWER SUPPLY, DRAIN VALVE IS FULLY CLOSED, NO WATER IS IN POT, CONTROLLER IS ON. Is POWER LED lit? Is WATER LED lit? Is unit filling with water? Once water reaches upper water level sensor, does filling stop...
  • Page 44 6.8.3 Troubleshooting the 24 VAC Circuit in FBRA18 Units (Continued) Is 24VAC present on N/O terminal of latch relay? Is 24VAC present on COM terminal of latch relay? Is 24VAC present on J1 pin When water level is above lower water level sensor, is CYCLE LED lit? Go to "B".
  • Page 45 6.8.3 Troubleshooting the 24 VAC Circuit in FBRA18 Units (Continued) Is 24VAC present across the gas valve main coil (PV) terminal? 24VAC present on VALVE terminal of LEFT ignition module? Is 24VAC present on 25V terminal of LEFT ignition module? Is 24VAC present on J2 pin 4?
  • Page 46 6.8.3 Troubleshooting the 24 VAC Circuit in FBRA18 Units (Continued) Is 24VAC present on J1 pin 5 when unit calls for heat? Is 24VAC present on N/O terminal of 12VDC relay? Probable cause is failed wiring between latch relay and 12VDC relay.

  • Page 47: Interface Board

    THE 24VAC CIRCUIT IN FBRA18 UNITS CONTROLLER 12VDC RELAY J2 PIN 2 INTERFACE BOARD J1 PIN 5 WATER WATER RELAY J2 PIN 1 WATER SOLENOID VALVE TRANSFORMER LATCH RELAY J1 PIN 3 POWER LOGIC CIRCUITRY CYCLE INTERFACE BOARD WIRING HARNESS PIN 5 WIRING HARNESS PIN 2 WIRING HARNESS PIN 4 6-20...

  • Page 48: Troubleshooting The Temperature Probe

    6.8.4 Troubleshooting the Temperature Probe DENTED, OR CRACKED. approximately equal to that given in the Probe Resistance Chart for the corresponding WHILE IT IS STILL IN THE COOKPOT, INSPECT THE PROBE BODY FOR DAMAGE. REPLACE IF BENT, Inspect leads for fraying, burning, breaks, and/or kinks.

  • Page 49: Probe Resistance Chart

    Probe Resistance Chart OHMS OHMS 1000 1107 1002 1110 1004 1112 1006 1114 1008 1116 1011 1118 1013 1120 1015 1122 1017 1124 1019 1126 1021 1128 1023 1131 1025 1133 1030 1135 1032 1137 1034 1139 1036 1141 1038 1143 1040 1145...

  • Page 50: Wiring Diagram For Fbr18 Units

    Wiring Diagram for FBR18 Units CABLE VOLTAGE HIGH MODULE IGNITION (BURNER) (BURNER) VALVE VALVE (GND) ALARM ALARM 6-23 MODULE IGNITION (GND)

  • Page 51: Wiring Diagram For Fbra18 Units

    6.10 Wiring Diagram for FBRA18 Units BLACK WHITE 6-24...

  • Page 52: Chapter 7: Parts List

    FBR18 & FBRA18 SERIES GAS RETHERMALIZERS CHAPTER 7: PARTS LIST Burner System Components ITEM PART # Burner Assemblies 806-5563 Natural Gas, Complete 806-5564SP Propane Gas, Complete 810-1382 Burner, Reverse Plenum, Universal Orifice 810-0916 Natural Gas, 3.26mm 810-0917 Propane Gas, 2.00mm Ignitor 810-0521 Natural Gas...

  • Page 53: Cabinetry And Associated Components

    Cabinetry and Associated Components ITEM PART # 910-1181 Retainer, Flue Cap Insulation 816-0157 Insulation, Flue 900-4603 Flue Guard 823-2107 Flue Cap 810-2263 Hanger, Basket 910-7434 Top Cap 900-7379 Back, Cabinet 900-7377 Side, Cabinet, CRS, Left or Right 900-4521 Retainer, Cabinet Back Insulation 812-1141 Insulation, Cabinet Back 900-1552...

  • Page 54: Control Box Assembly And Associated Parts, Fbr18/Fbra18

    ITEM PART # * Not illustrated Control Box Assembly and Associated Parts, FBR18/ FBRA18 GREEN LEFT IGNITOR RIGHT IGNITOR ITEM PART # 900-4509 Control Box Mounting Base 807-1006 Ignition Module, 4-Second Honeywell 809-0446 Spacer, .26-inch x .50-inch 807-1706 Cable, Ignition, 36-inch 806-5541 Wire, Flame Sensor 807-0855...

  • Page 55: Controller And Component Box Assemblies

    Controller and Component Box Assemblies Frymaster ITEM PART # 824-0396 Control Box (used on FBR18 only) 806-3398 Interface Board (used on FBR18 only) 809-0394 Spacer, Interface Board Standoff, 4mm x 6mm (used on FBR18 only) 810-0045 Bushing, .875-inch (used on FBR18 and FBRA18)

  • Page 56: Cooking Timer Control Panel Components

    Cooking Timer Control Panel Components ITEM PART # 910-4496 Cooking Timer Control Panel Knob Assembly 810-1287 Black 806-5339 Gray 806-5340 806-5341 Brown 806-5342 Blue 806-5343 Green 810-0808 Faceplate, Timer Dial 810-0807 Timer, Springwound, 60-Minute 807-1547 Lamp, Red Lens, 24V Trouble 806-5260SP Frame, Cooking Timer Control Panel Error! Not a valid link.

  • Page 57: Cookpot, Fbr18

    Cookpot, FBR18 ITEM PART # 900-1762 Retainer, Insulation 900-7431 Cover, Cookpot Front Insulation 816-0143 Insulation, Cookpot Front 823-1891SP Cookpot 816-0144 Insulation, Cookpot Side 806-5251SP Probe Assembly, Temperature 824-0395 Guard, Probe 900-1031 Retainer, Sight Glass 816-0053 Insulation, Sight Glass 814-0048 Sight Glass 810-0809 Block, Probe Mounting 816-0157...

  • Page 58: Cookpot, Fbra18

    Cookpot, FBRA18 This washer must be seated in hole before nut is tightened. Inside face of Torque nut to 30 in-lb ± 5. Enlarged View of Water Level Sensor Assembly ITEM PART # 900-1762 Retainer, Insulation 900-7431 Cover, Cookpot Front Insulation 816-0143 Insulation, Cookpot Front 823-4094SP Cookpot...

  • Page 59: Gas Supply Components

    Gas Supply Components ITEM PART # Gas Valve 810-0786 Natural Gas 810-0787 LP (Propane) Gas 813-0378 Fitting, Cross, ⅛” NPT, Brass 813-0154 Plug, Pipe, ⅛” Hex Head 813-0340 Adapter, ⅛” NPT x ⅛” Tube, Brass 813-0016 Nipple, ⅛” x ¾” NPT, BM 813-0004 Elbow, ⅛”...

  • Page 60: Plumbing Components

    Plumbing Components ITEM PART # 806-9067 Valve Assembly, Solenoid (FBRA18 only) 810-1208 Valve, Water Pressure Regulator (FBRA18 only) 900-2916 Bracket, Water Pressure Regulator Valve (FBRA18 only) 813-0448 Elbow, Pipe Fitting, Brass, ¼” (FBRA18 only) 813-0302 Elbow, Compression, ¼” NPT x ⅜” Tubing (FBRA18 only) 910-8027 Tubing, SS, Solenoid to Cookpot (FBRA18 only) 810-1025...
  • Page 61 7-10...

  • Page 62: Service Hotline

    Frymaster, L.L.C., 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) 1-318-219-7140 FAX (Tech Support) 1-318-219-7135 Price: $10.00 SERVICE HOTLINE 819-5278 PRINTED IN THE UNITED STATES 1-800-551-8633 May 2003...

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