Frymaster Gas Rethermalizers FBRA18 Series User Manual

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

FBR18 & FBRA18 SERIES GAS RETHERMALIZERS

TABLE OF CONTENTS

CHAPTER 1: General Information

1.1 Parts Ordering and Service Information ............................................................................1-1

1.2 Safety Information .............................................................................................................1-1

1.3 Equipment Description ......................................................................................................1-2

1.4 Installation, Operating, and Service Personnel..................................................................1-2

1.5 Definitions..........................................................................................................................1-2

1.6 Shipping Damage Claim Procedure...................................................................................1-3

CHAPTER 2: Installation Instructions

2.1 General Installation Requirements.....................................................................................2-1

2.2 Caster/Leg Installation.......................................................................................................2-2

2.3 Pre-Connection Preparations .............................................................................................2-2

2.4 Connecting to the Gas Supply............................................................................................2-4

2.5 Converting to Another Gas Type.......................................................................................2-5

CHAPTER 3: Operating Instructions

3.1 Introduction........................................................................................................................3-1

3.2 FBR18/FBRA18 Digital Controller...................................................................................3-1

Operating the FBR18/FBRA18 Digital Controller............................................................3-1

Operating the FBR18/FBRA18 Timers .............................................................................3-2

3.3 Start-Up Procedure.............................................................................................................3-2

3.4 Boiling Out the Cookpot....................................................................................................3-3

3.5 Shutting the Rethermalizer Down......................................................................................3-4

CHAPTER 4: Preventive Maintenance

4.1 Daily Checks and Services.................................................................................................4-1

4.2 Quarterly Checks and Services ..........................................................................................4-1

4.3 Semi-Annual Checks and Services ....................................................................................4-2

Clean Combustion Air Blower...........................................................................................4-2

Clean Gas Valve Vent Tube ..............................................................................................4-2

Check Burner Manifold Pressure.......................................................................................4-3

CHAPTER 5: Operator Troubleshooting

5.1 Introduction........................................................................................................................5-1

5.2 Operator Troubleshooting Guides......................................................................................5-2

5.3 Replacing the Computer or Computer Wiring Harness.....................................................5-6

CHAPTER 6: Service Procedures

6.1 Functional Description.......................................................................................................6-1

The Electronic Ignition System .........................................................................................6-1

Controller and Mechanical Timers ....................................................................................6-2

Interface Boards.................................................................................................................6-2

Temperature Probe ............................................................................................................ 6-3

Water Level Sensors (FBRA18 Only)............................................................................... 6-3

6.2 Accessing the Rethermalizer for Servicing....................................................................... 6-4

6.3 Cleaning the Gas Valve Vent Tube................................................................................... 6-4

6.4 Checking the Burner Manifold Gas Pressure.................................................................... 6-4

6.5 Measuring Flame Current.................................................................................................. 6-4

6.6 Replacing Components...................................................................................................... 6-5

6.6.1 Replacing the Controller or Controller Wiring Harness ................................................... 6-5

6.6.2 Replacing the Temperature Probe ..................................................................................... 6-5

6.6.3 Replacing the Interface Board........................................................................................... 6-5

6.6.4 Replacing an Ignition Module........................................................................................... 6-6

6.6.5 Replacing an Ignitor Assembly ......................................................................................... 6-6

6.6.6 Replacing the Combustion Air Blower ............................................................................. 6-7

6.6.7 Replacing the Gas Valve ................................................................................................... 6-7

6.6.8 Replacing a Burner Assembly........................................................................................... 6-7

6.6.9 Replacing the Cookpot ...................................................................................................... 6-8

6.7 Troubleshooting and Problem Isolation ............................................................................ 6-8

6.7.1 Ignition Failures ................................................................................................................ 6-9

6.7.2 Improper Burner Functioning.......................................................................................... 6-10

6.7.3 Improper Temperature Control ....................................................................................... 6-12

6.8 Troubleshooting Guides .................................................................................................. 6-12

6.8.1 Troubleshooting the Gas Valve....................................................................................... 6-13

6.8.2 Troubleshooting the 24 VAC Circuit in FBR18 Units.................................................... 6-14

6.8.3 Troubleshooting the 24 VAC Circuit in FBRA18 Units................................................. 6-16

6.8.4 Troubleshooting the Temperature Probe......................................................................... 6-21

Probe Resistance Chart.................................................................................................... 6-22

6.9 Wiring Diagram for FBR18 Units................................................................................... 6-23

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

CHAPTER 7: Parts List

7.1 Burner System Components.............................................................................................. 7-1

7.2 Cabinetry and Associated Components............................................................................. 7-2

7.3 Control Box Assembly and Associated Parts, FBR18/FBRA18....................................... 7-3

7.4 Controller and Component Box Assemblies..................................................................... 7-4

7.5 Cooking Timer Control Panel Components ...................................................................... 7-5

7.6 Cookpot, FBR18................................................................................................................ 7-6

7.7 Cookpot, FBRA18............................................................................................................. 7-7

7.8 Gas Supply Components ................................................................................................... 7-8

7.9 Plumbing Components ...................................................................................................... 7-9

FBR18 & FBRA18 SERIES GAS RETHERMALIZERS

CHAPTER 1: GENERAL INFORMATION

1.1

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.

Parts orders may be placed directly with your local FASC or distributor. Included with the unit

when shipped from the factory is a list of FASCs. If you do not have access to this list, contact the

Frymaster Technical Service Department at 1-800-551-8633 or 1-318-865-1711.

When ordering parts, the following information is required:

Model Number:

Serial Number:

Gas Type:

Item Part Number:

Quantity Needed:

Service information may be obtained by contacting your local FASC/Distributor. Information may

also be obtained by calling the Frymaster Technical Service Department at 1-800-551-8633 or

1-318-865-1711. When requesting service, please have the following information ready:

Model Number:

Serial Number:

Gas Type:

In addition to the model number, serial number, and gas type, please be prepared to describe the na-

ture of the problem and have ready any other information that you think may be helpful in solving

your problem.

RETAIN AND STORE THIS MANUAL IN A SAFE PLACE FOR FUTURE USE.

1.2

Safety Information

Before attempting to operate your unit, read the instructions in this manual thoroughly.

Throughout this manual, you will find safety notations enclosed in double-bordered boxes similar to

the ones illustrated on the following page.

1-1

CAUTION

CAUTION boxes contain information about actions or conditions that may cause or

result in a malfunction of your system.

WARNING

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

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.

1.3

Equipment Description

The FBR18 and FBRA18 Series Gas Rethermalizers are specifically designed to rethermalize meats,

sauces, and other vacuum packaged foods at a safe temperature range that prevents overcooking.

They can be configured for either natural or LP (Propane) gas, and their efficient infrared burners

deliver 90,000 BTUs (94.9 MJ – 26.4 kW).

The two models are identical except that the FBRA18 has an automatic filling (AutoFill) feature.

Both models feature digital temperature controls with continuous temperature display and individual

color-coded timer controls with corresponding color-coded baskets. Each unit can rethermalize up

to 15 lbs. (7 kg) of food an hour in large capacity 2-5 lb. (0.9-2.3 kg) baskets.

The rethermalizers are safeguarded against boil-over by a standpipe overflow drain, and come with a

1¼” cookpot drain for fast, clog-free emptying. The unit has a rethermalizing area of 18” x 24”

(457mm x 609mm) and holds 25 gallons (94.6 liters) of water.

1.4

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.

1.5

Definitions

QUALIFIED AND/OR AUTHORIZED OPERATING PERSONNEL

Qualified/authorized operating personnel are those who have carefully read the information in this

manual and have familiarized themselves with the equipment functions, or who have had previous

experience with the operation of the equipment covered in this manual.

1-2

QUALIFIED INSTALLATION PERSONNEL

Qualified installation personnel are individuals, or firms, corporations, or companies which, either in

person or through a representative, are engaged in and are responsible for the installation of electri-

cal and gas appliances. Qualified personnel must be experienced in such work, be familiar with all

electrical precautions involved, and have complied with all requirements of applicable national and

local codes.

QUALIFIED SERVICE PERSONNEL

Qualified service personnel are those that are familiar with Frymaster equipment and who have been

authorized by Frymaster to perform service on Frymaster equipment. All authorized service per-

sonnel are required to be equipped with a complete set of service and parts manuals, and to stock a

prescribed minimum amount of 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.

1.6

Shipping Damage Claim Procedure

Your Frymaster equipment was carefully inspected and packed before leaving the factory. The

transportation company assumes full responsibility for safe delivery upon acceptance of the equip-

ment for transport.

What to do if your equipment arrives damaged:

1. File a claim for damages immediately, regardless of the extent of damages.

2. Inspect for and record all visible loss or damage and ensure that this information is noted on

the freight bill or express receipt and is signed by the person making the delivery.

3. Concealed loss or damage that was unnoticed until the equipment was unpacked should be re-

corded and reported to the freight company or carrier immediately upon discovery. A concealed

damage claim must be submitted within 15 days of the date of delivery. Ensure that the shipping

container is retained for inspection.

Frymaster DOES NOT ASSUME RESPONSIBILITY

FOR DAMAGE OR LOSS INCURRED IN TRANSIT.

1-3

FBR18 & FBRA18 SERIES GAS RETHERMALIZERS

CHAPTER 2: INSTALLATION INSTRUCTIONS

2.1

General Installation Requirements

PROPER INSTALLATION IS ESSENTIAL FOR EFFICIENT, TROUBLE-FREE OPERATION OF YOUR

RETHERMALIZER. ANY UNAUTHORIZED ALTERATIONS MADE TO THIS EQUIPMENT WILL VOID

THE 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” (150mm) clearance at both sides and back when installed

adjacent to combustible construction. No clearance is required when installed adjacent to noncom-

bustible construction. A minimum of 24” (600mm) clearance should be provided at the front of the

unit.

One of the most important considerations of efficient operation is ventilation. Make sure the equip-

ment is installed so that products of combustion are removed efficiently, and that the kitchen ventila-

tion system does not produce drafts that interfere with proper burner operation.

The equipment flue opening must not be placed close to the intake of the exhaust fan, and the flue

must never be extended in a “chimney” fashion. An extended flue will change the combustion char-

acteristics of the equipment, causing longer recovery times. It also frequently causes delayed igni-

tion. To provide the airflow necessary for good combustion and burner operation, the areas sur-

rounding the front, sides, and rear of the unit must be kept clear and unobstructed.

This equipment must be installed in an area with an adequate air supply and adequate ventilation.

For U.S installations, information on construction and installation of ventilating hoods can be found

in NFPA Standard 96. This document can be ordered from the National Fire Protection Association,

Battery March Park, Quincy, MA 02269. For installations in countries other than the U.S., the ap-

propriate regulating authority should be contacted for information related to hood construction and

installation.

DANGER

Do not attach an apron drain to a single rethermalizer. The rethermalizer may be-

come unstable, tip over, and cause injury to personnel.

NATIONAL CODE REQUIREMENTS

This equipment is to be installed in compliance with the Basic Plumbing Code of the Building Offi-

cials and Code Administrators International, Inc. (BOCA) and the Food Service Sanitation Manual

of the U.S. Food and Drug Administration.

2-1

This equipment is manufactured to use the type of gas specified on the rating plate attached to the

door. Connect equipment stamped “NAT” only to natural gas and that stamped “PRO” only to LP

(Propane) gas.

Installation shall be made with a gas connector that complies with national and local codes. Quick

disconnect devices, if used, shall likewise comply with national and local codes.

ELECTRICAL GROUNDING REQUIREMENTS

All electrically operated appliances must be grounded in accordance with all applicable national and

local codes. A wiring diagram is located on the inside of the door. In the United States and Canada,

the electrical supply must be 120VAC, 60 Hz. In other countries, refer to the rating plate on the in-

side of the door for proper voltages.

FCC COMPLIANCE

The user is cautioned that any changes or modifications to Frymaster computers not expressly ap-

proved by the party responsible for compliance could void the user’s authority to operate the equip-

ment. 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. These limits are designed to provide reasonable

protection against harmful interference when the equipment is operated in a commercial environ-

ment. 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 com-

munications. Operation of the equipment in a residential area is likely to cause harmful interference

in which case the user will be required to correct the interference at his own expense. If necessary,

the user should consult the dealer or an experienced radio and television technician for additional

suggestions.

The user may find the booklet “How to Identify and Resolve Radio-TV Interference Problems” help-

ful. It is prepared by the Federal Communications Commission and is available from the U.S. Gov-

ernment Printing Office, Washington, DC 20402, Stock No. 004-000-00345-4.

2.2

Caster/Leg Installation

Your unit requires casters or legs to be installed. IT MAY NOT BE CURB MOUNTED!

If casters or legs are not already installed, install them in accordance the instructions included

in your accessory package. FAILURE TO INSTALL CASTERS OR LEGS WILL RESULT

IN IMPROPER OPERATION OF YOUR UNIT.

2.3

Pre-Connection Preparations

DANGER

Do not connect this equipment to the gas supply before completing each step in this

section.

2-2

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. If a flexible gas hose is used, a restraining cable must be con-

nected at all times when the equipment is in use.

2. The rethermalizer must be stabilized by installing restraining chains on units equipped with cast-

ers or anchor straps on units equipped with legs. Follow the instructions shipped with the cast-

ers/legs to properly install the chains or straps.

3. Level rethermalizers equipped with legs by screwing out the legs approximately 1 inch then ad-

justing them so that the rethermalizer is level.

4. For rethermalizers equipped with casters, there are no built-in leveling devices. The floor where

the rethermalizer is to be installed must be level.

5. Connect the water hose to the fitting at the rear of the unit.

NOTE 1: The hose comes with a quick-disconnect coupling. The quick disconnect may be at-

tached to the rethermalizer or to the water supply line, or it may be left off entirely, whichever

you prefer. Whichever of the options is chosen, Teflon thread-seal tape or Loctite™ PST56765

or equivalent thread sealer must be used when installing the fittings.

NOTE 2: Either hot or cold water may be connected to the unit. Connecting to hot water will

minimize the amount of time required to bring the unit to boil when filling with fresh water.

NOTE 3: In order for the water level sensors to work properly, a certain amount of mineral con-

tent in necessary in the water. For that reason, purified, deionized, or highly filtered water

should not be used.

4. Connect the desired drain plumbing to the 1¼” drain valve.

5. Test the equipment electrical system by plugging the power cord into a grounded 120VAC outlet

and pressing the controller’s ON/OFF button. After four (4) seconds, the last programmed set-

point temperature will display constantly.

6. Turn the controller off. Verify that the display is blank.

7. Verify that the minimum and maximum incoming gas pressures for the type of gas to be used are

in accordance with the accompanying table.

Incoming Gas Pressures

Gas

Minimum

Maximum

6" W.C.

1.49 kPa

14" W.C.

3.48 kPa

Natural

14.93 mbar 34.84 mbar

11" W.C.

2.74 kPa

14" W.C.

3.48 kPa

27.37 mbar 34.84 mbar

2-3

2.4

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 inches (38mm) ID.

When configured for natural gas, this equipment requires a standard gas pipe size of ¾ inch (19mm)

ID for connections within 20 feet (6m) of the supply line, provided no more than 4 fittings or elbows

are used in the run. For a pipe run over 20 feet (6m), increase the pipe size to 1 inch (25.4mm). For

use with LP (Propane) gas, the next smaller pipe size may be used.

IF IN DOUBT ABOUT THE PIPE SIZE TO BE USED, CONSULT YOUR LOCAL GAS

COMPANY.

DANGER

Before connecting new pipe to this equipment, the pipe must be blown out

thoroughly to remove all foreign material. Foreign material in the burner and gas

controls may cause improper and dangerous operation.

1. Connect the equipment to the gas supply line.

When making connections, apply a small amount of Loctitite^®PST 56765 or equivalent thread

compound to the male threads only. DO NOT apply the compound to the first two threads. This

will prevent clogging of the burner orifices and control valve.

2. Open the gas supply to the fryer and check all piping, fittings, and gas connections for leaks. A

soap and water solution should be used for this purpose.

DANGER

Never use matches, candles, or any other ignition source to check for leaks.

If gas odors are detected, shut off the gas supply to the fryer at the main shut-off

valve and contact the local gas company or an authorized service agency for service.

The rethermalizer and any shut-off valves installed between the rethermalizer and

the gas supply line must be disconnected from the gas supply line during any

pressure testing of the supply line at pressures equal to or greater than ½ PSIG

(3.45kPa, 13.84 inches W.C.).

3. Close the drain valve and fill the cookpot with water and boil-out solution to the overflow. Light

the burners and perform the boil-out procedures that are described in the “Start-Up Procedure”

and “Boiling Out the Cookpot” sections in Chapter 3 of this manual.

2-4

WARNING

“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. Refer to “Check Burner Manifold Pressure” in Chapter 4 of

this manual for the proper procedure.

2.5

Converting to Another Gas Type

This equipment is configured at the factory for either natural gas or LP (Propane) gas.

If you desire to switch from one type of gas to the other, a gas conversion kit must be installed by a

Factory Authorized Service Center technician.

DANGER

Switching to a different type of gas without installing the proper conversion kit may

result in fire or explosion! NEVER attach your fryer to a gas supply for which it is

not configured.

2-5

FBR18 & FBRA18 SERIES GAS RETHERMALIZERS

CHAPTER 3: OPERATING INSTRUCTIONS

3.1

Introduction

Mechanically, the FBR18 and FBRA18 rethermalizers are virtually identical, the only difference

being that the FBRA18 units have an automatic filling (AutoFill) feature. Both units use the same

digital temperature controller and mechanical timers.

In operation, a setpoint is programmed into the controller which then regulates burner firing to

maintain the water in the cookpot at the desired temperature. Six individual color-coded mechani-

cal timers allow different types or quantities of product to be rethermalized simultaneously. 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.

3.2

FBR18/FBRA18 Digital Controller

Celsius or

Fahrenheit

Display Switch

Power

Switch

Digital

Display

9 . 9

Frymaster

Temperature

or Setpoint

Display Switch

Setpoint

Adjustment

Arrows

Melt

Cycle

Switch

Heating

Mode

Indicator

OPERATING THE FBR18/FBRA18 DIGITAL CONTROLLER

WARNING

Ensure the cookpot is filled with water before turning the controller on. “Dry firing”

will cause damage to the cookpot!

1. Turn the controller on by pressing the Power

switch. The controller software version num-

ber will display for 4 seconds in the digital display then change to the last programmed setpoint

temperature.

3-1

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. At that time, it will enter the

continuous heat mode. When in the continuous heat mode the Heat Mode indicator (a decimal

point between the first two digits of the temperature display) will appear. When the setpoint is

reached, the Heat Mode indicator will go out, indicating the rethermalizer is ready for use.

3. To enter or change the setpoint temperature, press the up

arrow key to raise the setpoint or

the down arrow keys to lower the setpoint. The display will change at a rate of about 1

degree per second for approximately the first 12 degrees, then change at a faster rate if the

arrow is continuously pressed.

4. Pressing the Temperature/Setpoint display

switch toggles the display back and forth be-

tween constant temperature display and constant setpoint display. Use this feature if you want

to check the actual cookpot temperature.

5. To turn the controller (and burners) off, press the Power

switch.

OPERATING THE FBR18/FBRA18 TIMERS

1. Place a packet of product in one of the rethermalizing baskets and note the handle color of the

basket.

2. Place the basket into the water and rotate the correspondingly colored timer knob to the desired

rethermalizing time, up to 60 minutes.

3. An alarm will sound when the rethermalizing time has elapsed.

3.3

Start-Up Procedure

CAUTION

If this is the first time the unit is being used after installation, refer to Section 3.4,

Boiling-Out the Cookpot.

Before turning the rethermalizer on, ensure that:

• the unit is connected to the water supply

• the water supply is turned on

• the unit is plugged into a 120VAC outlet

• the electrical power supply to the rethermalizer is turned on

• the gas supply to the rethermalizer is turned on.

3-2

1. Turn the gas valve to the ON position (see illustration below).

2. Press the controller Power

switch.

On FBR18 models, the burners will light for several seconds then go out. A few seconds later

they will light again. This cycle will repeat seven times or until the water in the cookpot

reaches 160°F (71°C), whichever comes first, at which time the burners will remain lit until the

setpoint is reached.

On FBRA18 models, if the cookpot is not already full of water, the AutoFill feature will im-

mediately begin adding water. When the water level reaches the upper water level sensor, the

AutoFill solenoid valve will cut off the water flow. (If the water level drops below the upper

water level sensor during operation, the AutoFill solenoid valve will open and add water to the

cookpot). When the water level is above the lower water level sensor, the burners will light for

several seconds then go out. A few seconds later they will light again. This cycle will repeat

seven times or until the water in the cookpot reaches 160°F (71°C), whichever comes first, at

which time the burners will remain lit until the setpoint is reached.

3. When the burners have been lit continuously for at least 90 seconds, observe the burners

through the burner viewing ports. The burners should display a bright orange-red glow. If a

blue flame is observed, or if there are dark spots on a burner face, the air/gas mixture requires

adjustment. Refer to Chapter 4, Section 4.4, Clean Combustion Air Blower for adjustment pro-

cedures.

3.4

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.

2. Place the unit into operation in accordance with Section 3.3.

3. Program the setpoint for 200°F (93°C). When the Heat Mode indicator (decimal between the

first two digits of the display) goes out, set one of the product timers for 60 minutes.

4. After the solution simmers for an hour, turn the unit off, allow the solution to cool, then add 2

gallons (7.75 liters) of cold water and stir. Drain the solution and clean the cookpot thoroughly.

5. Rinse the cookpot at least twice by filling with clean water and draining.

3-3

6. Reprogram the setpoint to the appropriate temperature.

3.5 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.

CAUTION

The electronic circuitry in your controller can be adversely affected by current

fluctuations and electrical storms. Should it fail to function or program properly for

no apparent reason, unplug the controller and plug it back in to reset it. This could

prevent a service call.

3-4

FBR18 & FBRA18 SERIES GAS RETHERMALIZERS

CHAPTER 4: PREVENTIVE MAINTENANCE

4.1

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. Wipe all accessible metal surfaces and components

to remove accumulations of oil, dust, or cooking residue.

Clean the outside of the cabinet with a clean cloth dampened with dishwashing detergent, removing

oil, dust, or cooking residue.

DANGER

Never attempt to clean rethermalizer during the rethermalizing process or when the

cookpot is filled with hot water and/or food products.

Clean Water-Level Sensors, Temperature Probe, and Cookpot

Press the controller power switch to the OFF position.

FBRA18 Units: Remove the cap nut at the top of the shield (located on the left front of the cook-

pot) and remove the shield by lifting up until it can be removed from the stud that holds it at the

bottom. Clean the exposed screw heads with a solution of detergent and water. A Scotchbrite™ or

equivalent nylon pad may be used to scrub away any accumulated mineral deposits.

FBR18 & FBRA18 Units: Clean the temperature probe, located on the lower front centerline of

the cookpot, using a small bottlebrush wet with a solution of detergent and water.

Using a Scotchbrite™ or similar abrasive pad and a solution of detergent and water, clean the inside

of the cookpot.

Rinse the cookpot thoroughly with clean water at least twice.

4.2

Quarterly Checks and Services

Check Digital Controller Set Point Accuracy

1. Fill the cookpot with water. Press the controller power switch. When the Heat Mode indicator

(decimal between the first and second digits of the display) goes out, insert a good-grade

thermometer or pyrometer probe into the cookpot, with the end touching the temperature probe

at the lower front centerline of the cookpot and wait one minute.

4-1

2. Press the Temperature Display

switch once to display the temperature of the water as sensed

switch again to display the set

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. If either set of readings is outside its range, contact a Factory

Authorized Service Center for assistance.

4.3

Semi-Annual Checks and Services

Clean Combustion Air Blower

1. Unplug the rethermalizer.

2. There are 4 wires (2 orange, 1 white, and 1 black) running from the motor. Remove the wire

nuts and disconnect these wires from the rethermalizer wiring harness, marking each to ensure

proper reconnection.

3. Remove the 4 nuts and bolts securing the blower to its mounting bracket and remove the blower

from beneath the rethermalizer.

4. Remove the 3 motor flange nuts from the side of the blower housing and remove the motor and

blower wheel from the housing.

5. Wrap the motor with plastic wrap to prevent water from entering it. Spray degreasing detergent

on the blower wheel and blower housing. Wait 5 minutes, then rinse under hot water, being

careful not to get water into the motor. Dry with a clean cloth.

6. Reverse steps 1-5 to reinstall the blower.

7. Light the rethermalizer in accordance with the procedure described in Chapter 3, Section 3.1.

8. After the burners have been lit for at least 90 seconds, observe the flames through the burner

viewing ports. The air/gas mixture is properly adjusted when the burner manifold gas pressure

is in accordance with the table on page 4-3 and the burners display a bright orange-red glow. If

a blue flame is observed, or if there are dark spots on a burner face, the air/gas mix requires ad-

justment.

On the side of the blower housing opposite the motor is a plate with one or two locking nuts.

Loosen the nut(s) enough to allow the plate to be moved, then adjust the position of the plate to

open or close the air intake opening until a bright orange-red glow is obtained. Carefully hold

the plate in position and retighten the nut(s).

Clean Gas Valve Vent Tube

1. Set the rethermalizer power switch and the gas valve to the OFF position.

2. Carefully unscrew the vent tube from the gas valve. NOTE: The vent tube may be straightened

for ease in removal.

4-2

Vent Tube

3. Pass a piece of ordinary binding wire (.052 inch diameter) through the tube to remove any

obstruction.

4. Remove the wire, then blow through the tube to ensure it is clear.

5. Reinstall tube and bend so that the opening is pointing downward.

Check Burner Manifold Pressure

WARNING

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.

2. Remove the pressure tap plug from the gas valve assembly and attach the fitting for a gas

pressure-measuring device to the tap.

Pressure

Tap Plug

Regulator Cap

3. Place the gas valve in the ON position. Place the controller power switch in the ON position.

When the burner lights and continues to burn, compare the indicated pressure to the table

below.

4-3

Burner Manifold Gas

Pressures

Gas

Pressure

3.5" W.C.

0.8 kPa

Natural

8.25" W.C.

2.5 kPa

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.

4-4

FBR18 & FBRA18 SERIES GAS RETHERMALIZERS

CHAPTER 5: OPERATOR TROUBLESHOOTING

5.1

Introduction

This chapter provides an easy reference guide to the more common problems that may occur during

the operation of your equipment. The troubleshooting guides in this chapter are intended to help you

correct, or at least accurately diagnose, problems with your equipment. Although the chapter covers

the most common problems reported, you may very well encounter a problem not covered. In such

instances, the Frymaster Technical Service Department 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 a cord into a receptacle or open the valve on the water supply line. Don’t assume that you

are exempt from such occurrences.

Always try to establish a clear idea of why a problem has occurred. Part of your 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 while you’re at it. If a fuse continues to blow, find

out why. 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.

Each guide begins with a description of a common problem in a six-sided figure. Simply follow the

arrows and answer the questions to determine the corrective action to take. 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.

DANGER

Hot water can cause severe burns. Never attempt to move a rethermalizer

containing hot water or to transfer hot water from one container to another.

DANGER

Use extreme care when performing electrical circuit tests. Live circuits will be

exposed.

WARNING

Inspection, testing, and repair of electrical equipment should be performed only by

qualified service personnel. The equipment should be unplugged when servicing,

except when electrical tests are required.

5-1

5.2

Troubleshooting Guides

COOKPOT DID NOT FILL

WHEN UNIT WAS TURNED ON.

WATER SUPPLY TO UNIT

VERIFIED TO BE ON.

NOTE: This guide applies

to FBRA18 units only.

Controller is not functioning.

Did anything appear

in controller display when unit

was turned on?

Probable causes are failed 12V

transformer, failed interface

board, or failed controller.

Yes

Open control panel by

removing screws in

each upper corner.

Is WATER

LED on interface board

illuminated?

Yes

Use bottlebrush to

clean water level

sensors.

Probable causes are a failed

interface board or

Did LED

failed/loose high-level water

sensor wiring.

illuminate?

Yes

Probable causes are a failed

water solenoid or a failed

interface board.

Problem

resolved.

Did unit begin

to fill?

Yes

Call FASC.

5-2

WATER DID NOT SHUT

OFF WHEN COOKPOT

WAS FULL.

NOTE: This guide applies

to FBRA18 units only.

Use bottlebrush to clean

water level sensors.

Problem

resolved.

Did water

stop?

Yes

Add 1/8 cup of salt to

water in cookpot and

stir.

Mineral content of water is

insufficient for water sensor to

detect it. Whenever cookpot is

refilled, add 1/8 cup of salt.

Did water

stop?

Yes

Open control panel by

removing screws in each

upper corner.

Remove the cover over the

water sensors and thoroughly

clean the sensors with a

Is WATER

LED on interface board

illuminated?

Probable cause is failed

water solenoid.

Yes

Scotchbrite or similar pad.

If water still does not stop,

probable cause is

failed/loose high water

sensor wiring.

Call FASC.

5-3

WATER NOT HEATING.

AUTOFILL (IF INSTALLED)

WORKED PROPERLY.

Press the Temperature

Check button twice to

display setpoint.

Program setpoint in

accordance with instructions

in Chapter 3.

Has the correct setpoint

been programmed?

Yes

Refer to troubleshooting

guide "BURNERS DO NOT

LIGHT".

Did burners

light?

Yes

Insert a good grade thermometer into

cookpot with tip near temperature

probe and wait two minutes. Press

the Temperature Check button once to

display cookpot temperature.

Did water reach

setpoint temperature?

Yes

Is temperature

displayed reasonably

close to thermometer

reading?

There is a problem in

temperature probe

circuit. Call FASC.

Problem

resolved.

Yes

Temperature control

features are working properly.

If water still fails to reach

setpoint, call FASC.

5-4

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?

Problem

resolved.

Yes

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.

Did burners

light?

Problem

resolved.

Yes

Open control panel by

removing screws in

each upper corner.

Is HEAT LED

on interface board

illuminated?

Problem is with the gas

supply or ignition system.

Call FASC.

Yes

Problem is with a

failed interface board or a

malfunctioning computer.

Call FASC.

5-5

5.3

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. Disconnect the wiring harness from the back of the controller. If replacing the harness, discon-

nect it from the interface board, install the new harness, and then reverse steps 1 and 2 to

complete the process.

4. Disconnect the ground wire from the controller. Remove the control panel by lifting it from the

hinge slots in the frame.

If substituting one complete control panel for another, reverse steps 1-4 to complete the

procedure.

If replacing the controller, remove the nuts securing the controller to the control panel and install

the replacement controller on the control panel. Reverse steps 1-4 to complete the procedure.

Wiring Harness

Connection

Ground Wire

5-6

FBR18 & FBRA18 SERIES GAS RETHERMALIZERS

CHAPTER 6: SERVICE PROCEDURES

6.1

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.

Two self-contained combustion chambers (referred to as “burners”) are located beneath the cookpot.

Each combustion chamber is fitted with special ceramic tiles that are heated by the burning of a

forced air/gas mixture. The tiles transfer their heat to the cookpot by means of infrared radiation,

providing much more constant and uniform heat dispersion over the surface of the cookpot than do

conventional burners. Because relatively less heat is lost to the atmosphere in the process, compared

to “open-burner” designs, less fuel is required to achieve and maintain a given cookpot temperature.

Gas flow to both of the burners is regulated by one electromechanical gas valve.

THE ELECTRONIC IGNITION SYSTEM

Ignition modules, located in the component box, are

connected to ignitor assemblies at each burner. An

Inside the Ignition Module

ignition module performs four important functions: it

Out to

provides fuse protection for the 24-volt circuit, provides

Gas Valve

an ignition spark, supplies voltage to the gas valve, and

To Alarm

proofs the burner flame. The module contains a 4-

second time delay circuit and a coil that activates the

25 V +

gas valve.

Coil

The ignitor assembly consists of a spark plug, an

enrichment tube, and a flame sensor.

25 V GND

At start-up, the power switch is placed in the ON

position, supplying approximately 12-volts DC to the

heat control circuitry in the controller and to one side of

the heat relay coil on the interface board. If resistance

Ignition Wire

Flame Sensor

in the temperature probe indicates the temperature in the cookpot is below 160ºF (71ºC), the current

flows through a warm-up circuit containing a timer switch that alternately closes for 4 seconds and

opens for 24 seconds. If the temperature is 160ºF (71ºC) or above, the current flows through a heat

circuit, bypassing the timer switch. In either case, ground is supplied to the other leg of the heat re-

lay coil, which then closes an electronic switch in the 24 VAC circuit to provide current to the igni-

tion module.

Circuitry in the ignition module sends 24 VAC to the gas valve. Simultaneously, the module causes

the ignitor to spark for 4 seconds to light the burner. A flame sensor verifies that the burner is lit by

measuring the flow of microamps through the flame. If the burner does not light (or is extin-

6-1

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. This in turn cuts off the 24 VAC to the ignition module, causing the gas

valve to close.

CONTROLLER AND MECHANICAL TIMERS

FBR18 and FBRA18 Series rethermalizers are equipped with a digital controller that allows the op-

erator to enter or adjust a specific rethermalizing temperature for the cookpot. The controller does

not control rethermalizing times. Rethermalizing times for up to six different products are specified

by means of 60-minute mechanical timers arrayed across the front of the unit.

INTERFACE BOARDS

An interface board is located in the component box directly behind the control panel. The interface

board provides a link between the controller and the rethermalizer’s individual components without

requiring excessive wiring, and it allows the controller to execute commands from one central point.

FBR18 and FBRA18 models use different interface boards. The boards are not interchangeable.

FBR18 rethermalizers have been manufactured with two different interface boards, similar in ap-

pearance to the ones illustrated below. Regardless of the board used when manufactured, the uni-

versal replacement part is 806-3398. Earlier design boards may be replaced with later design

boards and vice versa.

SOUND

GND

SOUND

GND

AIR

12V

K3 K4

GND

V2D

PWR

GND

V1D

PWR

ALR

V1S

GND

V2D

Blower

Motor

2 Amp

BLOWER

MOTOR

RELAY

NOT

USED

NOT

USED

NOT

USED

GND

V1D

USED

PWR

HEAT

RELAY

AND

BLOWER

MOTOR

RELAY

NOT

USED

HEAT

ALR

V1S

24V

RELAY

PWR

NOT

USED

V2S

PWR

GND

GV PWR

PWR

GND

AL 12V AIR 24V AL

EARLIER DESIGN INTERFACE BOARD P/N 806-3398

LATER DESIGN INTERFACE BOARD P/N 806-3398

In earlier versions, nine diagnostic LEDs are arrayed along the bottom edge of the board. Each of

the LEDs is labeled with two or three letters indicating its function, and six of them are numbered.

In later versions, there are seven LEDs scattered around the board. All of these LEDs are labeled

and numbered. The diagnostic purposes of LEDs 1 through 6 on one board correspond directly to

those of LEDs 1 through 6 on the other board. When lit, LED 3 indicates the 24VAC is being re-

ceived from the transformer. LEDs 2 and 4, when lit, indicate that 24VAC is being supplied to the

left and right ignition modules respectively. LED 5, when lit, indicates that 24VAC is being sup-

plied to the gas valve. A lit LED 6 indicates that 12VAC is being received from the transformer.

All other LEDs have no diagnostic purpose in rethermalizer applications.

6-2

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. In later design boards, relay K3

serves as both the heat relay and blower motor relay.

FBRA18 rethermalizers use interface board 806-9592, often referred to as a water board.

HEAT

WATER

BLOWER

CYCLE WATER BLOWER

INTERFACE BOARD P/N 806-9592

On interface board 806-9592, the heat (or cycle) relay (K1) switches 24VAC to the ignition and gas

valve circuits when the controller’s heat logic circuit calls for heat and the lower water level sensor

is grounded (i.e., the water level in the cookpot is above the lower water level sensor). If the water

level in the cookpot is below the upper water level sensor, the water relay (K2) closes, switching

power to the normally closed water solenoid valve, causing it to open. When the water level reaches

the upper sensor, the relay opens, cutting power to the valve, causing it to close. The blower relay

(K3) closes and switches 120VAC to the blower motor only when the heat relay (K1) is closed. The

board has four LEDs to assist in troubleshooting. Three of the LEDs (CYCLE, WATER, and

BLOWER) are arrayed along the lower edge of the board. The fourth LED (POWER) is located at

the right edge of the board. When the cycle, water, and blower LEDs are illuminated, they indicate

that the associated relay is closed. The power LED indicates that 24VAC is being supplied to the

interface board by the transformer.

TEMPERATURE PROBE

A temperature probe is located on the front centerline of the cookpot. The probe is a type of thermo-

stat in which the resistance varies directly with the temperature. That is, as the temperature changes,

so does resistance, at a rate of approximately 2 ohms for every 1° of rise or fall. Circuitry in the

controller monitors the probe resistance and controls burner firing when the resistance exceeds or

falls below a programmed temperature (setpoint). The temperature is programmed by means of up

or down arrow buttons on the face of the controller.

WATER LEVEL SENSORS (FBRA18 Only)

A pair of water level sensors is arranged one above the other on the left front of the FBRA18 cook-

pot. When water contacts the sensors they are grounded. The lower sensor acts as a safety device to

keep the burner from firing when there is no water in the cookpot. When the sensor is grounded by

contact with water, a transistor on the interface board is biased and the heat relay (K1) pulls in, sup-

plying power to the blower via relay K3 and to the gas valve via the ignition modules. Grounding

6-3

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.

6.2

Accessing the Rethermalizer for Servicing

DANGER

Moving a rethermalizer filled with hot water may cause spilling or splattering of the

hot water. Always drain the cookpot before attempting to relocate the unit for servic-

ing.

1. Shut off the gas supply to the unit. Unplug the electrical power cord. Disconnect the unit from

the gas supply.

2. Remove any attached restraining devices.

3. Relocate the rethermalizer for service accessibility.

4. After servicing is complete, reconnect the unit to the gas supply, reattach restraining devices, and

plug in the electrical power cord.

6.3

Refer to Semi-Annual Checks and Services in Chapter 4, Preventive Maintenance.

6.4 Checking the Burner Manifold Gas Pressure

Refer to Semi-Annual Checks and Services in Chapter 4, Preventive Maintenance.

6.5 Measuring Flame Current

Cleaning the Gas Valve Vent Tube

When the burner flame is properly adjusted, it will produce a current between 3.5 µA and 6.5 µA.

Flame current is measured by placing a microamp (not milliamp) meter in series with the white sens-

ing wire on the ignitor. This is accomplished as follows:

1. Turn the unit OFF (press the

button).

Flame Sensor

Wire

Ignitor Wire

2. Disconnect the white flame sensor wire

from one of the burner ignitor assemblies

and connect it to the positive lead of the

meter. Connect the negative lead of the

meter to the terminal from which the

sensing wire was removed.

3. Turn the unit ON (press the

button).

When a cold unit is first turned on, the

burner will cycle on and off repeatedly

until the temperature in the cookpot

reaches 180°F (82°C). When the water in

6-4

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

6.6.1 Replacing the Controller or Controller Wiring Harness

Refer to Chapter 5, Section 5.3 for this procedure.

6.6.2 Replacing the Temperature Probe

1. Unplug the rethermalizer and drain the cookpot.

2. Remove the screws from the upper corners of the timer panel and swing the panel open from the

top, allowing it to rest on its hinge tabs. Cut the probe leads off at the rear of the probe. NOTE:

Once the probe leads have been cut, the probe cannot be reused. Work the Tinnerman retaining

clip rearward off the probe.

3. Remove the two screws securing the probe cover to the probe block and remove the cover. Slip

the failed probe out of the block from the cookpot side and replace with a new probe. Carefully

remove the Tinnerman retaining clip from the replacement probe to allow the leads and short end

of the probe to be inserted through the probe block from cookpot side. When the replacement

probe has been inserted, work the retaining clip onto the probe until the probe is held securely in

place. Reinstall the probe cover and timer panel.

4. Remove the screws from the upper corners of the control panel and swing the panel open from

the top, allowing it to rest on its hinge tabs. Remove the two upper screws securing the compo-

nent box to the rethermalizer. Rotate the box forward and outward to expose the 12-pin connec-

tor on the rear of the interface board.

5. Unplug the 12-pin connector from the interface board. Using a pin pusher, remove the cut off

pieces of wire from the connector one at a time, and insert the corresponding wire from the new

probe.

6. Reattach the 12-pin connector to the interface board, rotate the component box back into posi-

tion, and replace and tighten the mounting screws. Close the control panel and replace the

screws in each upper corner.

6.6.3 Replacing the Interface Board

1. Unplug the rethermalizer and drain the cookpot.

2. Remove the screws from the upper corners of the control panel and swing the panel open from

the top, allowing it to rest on its hinge tabs.

3. Detach the grounding wire from the controller, unplug the 15-pin connector from the interface

board, and remove the control panel from the unit by lifting it up and out of the hinge slots in the

control panel frame.

6-5

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).

5. Remove the nuts in each corner of the interface board and carefully pull the board off the mount-

ing studs, being careful not to dislodge the spacers on the studs.

6. Position the replacement board on the studs and replace the four nuts.

7. Reconnect the water level sensor wires (FBRA18 models only) and the 12-pin connector to the

interface board.

8. Rotate the component box back into position and replace and tighten the mounting screws. Re-

mount the control panel to the component box and reattach the grounding wire.

9. Reattach the 15-pin connector to the interface board.

10. Close and secure the control panel.

6.6.4 Replacing an Ignition Module

1. Unplug the rethermalizer and drain the cookpot.

2. Disconnect the ignitor wire and flame sensor wire from the right burner assembly.

3. Remove the five screws from the rear of the transformer box and pull the box out of the unit suf-

ficiently to allow the removal of the five screws in the cover of the box. Remove the cover.

4. Unplug the ignitor wire and flame sensor wire from the module to be replaced. Disconnect the

remaining wires from the ignition module one at a time and mark them to facilitate reconnection.

5. Remove the four screws securing the module in place and lift the module out of the box. Re-

move the four spacers from the back of the failed module and insert them into the holes on the

replacement module, tapered end in.

6. Reverse steps 1 through 5 to complete the procedure.

6.6.5 Replacing an Ignitor Assembly

1. Unplug the rethermalizer and drain the cookpot.

2. Remove the ignitor wire and flame sensor wire from the ignitor assembly. Disconnect the gas

enrichment tube from the assembly.

3. Remove the two mounting screws and pull the ignitor assembly out of the burner.

4. Install the replacement ignitor assembly.

6-6

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. Turn off the gas supply to the rethermalizer, unplug the unit, and drain the cookpot.

2. Disconnect the unit from the gas supply line and remove any fitting that may be attached to the

gas manifold at the rear of the unit.

3. Disconnect the gas lines at each burner orifice.

4. Disconnect the gas enrichment tubes at the gas valve cross fitting.

5. Disconnect the wires from the gas valve terminal, marking each wire to facilitate reconnection.

6. Remove the two nuts securing the gas manifold bracket to the base frame.

7. Pull the gas manifold assembly out the front of the unit.

8. Remove the gas valve from the manifold assembly and remove all fittings from the old valve.

9. Install the fittings removed from the old valve on the new valve, using Loctite^®PST56765 or

equivalent pipe thread sealant.

10. Apply Loctite^®PST56765 pipe thread sealant or equivalent to the threads of the manifold and

install the new gas valve.

11. Position the gas manifold system in the unit and replace the two nuts removed in step 6.

12. Reverse steps 1-5 to complete installation.

13. Check burner manifold gas pressure in accordance with procedure given in Chapter 4.

6.6.8 Replacing a Burner Assembly

(NOTE: If space permits, it is recommended that the unit be disconnected from the gas line and laid

on its back when performing this procedure. Be sure to place blocks under the unit to protect the

end of the gas line.)

1. Unplug the rethermalizer.

2. Disconnect the flexible gas line at the burner orifice.

3. Remove both air hoses from the blower assembly and the burner assemblies.

6-7

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. It is not necessary to disconnect the blower wiring.

6. Remove the two screws at the front of the burner assembly to be replaced, then pull the assembly

toward the front of the unit slightly to free it from its rear support. Remove the assembly

through the bottom of the unit.

7. Reverse steps 1-6 to install replacement burner assembly, being careful to get the insulation strip

running along the top of the blower support bracket back in place.

6.6.9 Replacing the Cookpot

1. Remove the cookpot insert.

2. Remove the top cap by removing the two screws on the front and the screw on each end.

3. Remove the flue cap and lid assembly by removing the two screws on each side and the two out-

ermost screws on the back. Rotate the bottom of the flue cap forward slightly to allow the top of

the flue cap to slip out from under the back panel.

4. Remove the four screws securing the upper flue assembly to the back panel.

5. Remove the blower motor by removing the four nuts securing it to blower mounting bracket.

6. Disconnect the flexible gas lines, gas enrichment tubes, ignitor wires, and flame sensor wires

from the burner assemblies.

7. Remove the temperature probe from the cookpot. Leave wires attached.

8. Disconnect the water fill line at the cookpot and at the solenoid valve inlet.

9. Disconnect the wires from the water level sensors, marking them to facilitate reconnection.

10. Lift the cookpot assembly out of the cabinet and set it, top down, on a suitable work surface.

11. Remove all other hardware from the old cookpot and install the components on the replacement

cookpot, using Loctite^®PST56765 on the drain valve threads. (NOTE: Install any replacement

insulation that might be required before installing components.)

12. Reverse steps 1-10 to install the replacement cookpot.

6.7

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

6-8

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. Ignition failures

2. Improper burner functioning

3. Improper temperature control

4. Controller-related problems

5. Autofill system problems.

The probable causes of each category are discussed in the following sections. A series of trouble-

shooting guides (decision trees) is also included at the end of the chapter to assist in identifying

some of the more common problems.

6.7.1 Ignition Failures

Ignition failure occurs when the ignition module fails to sense a flame within 4 seconds and locks

out. When this happens, the module sends 24 VAC through the interface board alarm circuit to the

controller and the trouble light on the timer control panel lights.

The three primary reasons for ignition failure, listed in order of probability, are:

1. Problems related to the gas and/or electrical power supplies.

2. Problems related to the electronic circuits.

3. Problems related to the gas valve.

PROBLEMS RELATED TO THE GAS AND/OR ELECTRICAL POWER SUPPLIES

The main indicator of a problem with the electrical power supply is that there are no indicator lights

illuminated on the unit. The main indication of a problem with the gas supply is failure of the unit to

fire. Verify that the gas line quick-disconnect fitting (if used) is properly connected, the unit is

plugged in, the main gas supply valve is open, and the circuit breaker for the unit’s electrical supply

is not tripped.

PROBLEMS RELATED TO THE ELECTRONIC CIRCUITS

If gas and electrical power are being supplied to the rethermalizer, the next most likely cause of igni-

tion failure is a problem in the 24 VAC circuit. First, verify that the drain valve is fully closed. (The

drain valve assembly includes a microswitch that must be closed for power to reach the gas valve.

Often, although the valve handle appears to be in the closed position, the microswitch is still open.)

If the drain valve is fully closed, refer to the troubleshooting guide TROUBLESHOOTING THE 24 VAC

CIRCUIT.

Some typical causes of ignition failure in this category include a defective sensing wire in the ignitor

assembly, a defective module, a defective ignition wire, or a defective ignitor. Occasionally an igni-

6-9

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.

PROBLEMS RELATED TO THE GAS VALVE

If the problem is not in the 24 VAC circuit, it is most likely in the gas valve itself, but before replac-

ing the gas valve, refer to the troubleshooting guide TROUBLESHOOTING THE GAS VALVE.

6.7.2 Improper Burner Functioning

With problems in this category, the burner ignites but exhibits abnormal characteristics such as

“popping,” dark spots on the burner ceramics, fluctuating flame intensity, and flames shooting out of

the flue.

“Popping” indicates delayed ignition. In this condition, the main gas valve is opening but the burner

is not immediately lighting. When ignition does take place, the excess gas “explodes” into flame,

rather than smoothly igniting.

The primary causes of popping are:

ꢀ

Incorrect or fluctuating gas pressure

A defective, dirty, or incorrectly adjusted combustion air blower

Inadequate make-up air

Heat damage to the controller or ignition module

A cracked ignitor or broken/loose ignition wire

A defective ignition module

A cracked burner tile.

If popping occurs only during peak operating hours, the problem is most likely incorrect or fluctuat-

ing gas pressure. Verify that the incoming gas pressure (pressure to the gas valve) is in accordance

with the following table, and that the pressure remains constant throughout all hours of usage.

Incoming Gas Pressures

Gas

Minimum

Maximum

6" W.C.

1.49 kPa

14" W.C.

3.48 kPa

Natural

14.93 mbar 34.84 mbar

11" W.C.

2.74 kPa

14" W.C.

3.48 kPa

27.37 mbar 34.84 mbar

Refer to Check Burner Manifold Pressure in the Semi-Annual Checks and Services section of

Chapter 4 for the procedure for checking the gas pressure supplied to the burner.

6-10

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.

If the rethermalizer’s gas and air supplies are okay, the problem is most likely with one of the elec-

trical components. Examine the ignition module and controller for signs of melting/distortion and/or

discoloration due to excessive heat build-up in the equipment. (This condition usually indicates im-

proper flue performance.) A melted or distorted ignition module is automatically suspect and should

be replaced, but unless the condition causing excessive heat is corrected, the problem is likely to re-

cur.

Verify that the ignition wire is tightly connected at both ends and free of obvious signs of damage.

Again, if damage is due to excessive heat in the equipment, that problem must also be corrected.

Check for proper operation by disconnecting the wire from the ignitor, inserting the tip of a screw

driver into the terminal, and holding it near the frame of the unit as the power switch is placed in the

on position. A strong blue spark should be generated for at least 4 seconds.

DANGER

Make sure the insulated handle of the screwdriver is held and not the blade. The

sparking charge is approximately 25,000 volts.

Examine the ignitor for any signs of cracking. A cracked ignitor must be replaced.

If all other causes have been ruled out, examine the burner tiles for any signs of cracking. If found,

the burner must be replaced.

Fluctuating flame intensity is normally caused by either improper or fluctuating incoming gas pres-

sure, but may also be the result of variations in the kitchen atmosphere. Verify incoming gas pres-

sure in the same way as for popping discussed in the preceding paragraphs. Variations in the kitchen

atmosphere are usually caused by air conditioning and/or ventilation units starting and stopping dur-

ing the day. As they start and stop, the pressure in the kitchen may change from positive or neutral

to negative, or vice versa. They may also cause changes in airflow patterns that may affect flame

intensity.

Dark spots on the burner tiles are the result of an improper air/gas mixture. Adjust the combustion

air blower to reduce the amount of air in the mixture to correct this problem.

Flames shooting out of the flue are usually an indication of negative pressure in the kitchen. Air is

being sucked out of the burner enclosure and the flames are literally following the air. If negative

pressure is not the cause, check for high burner manifold gas pressure in accordance with the proce-

dures in Chapter 4.

An excessively noisy burner, especially with flames shooting out of the flue, may indicate that the

gas pressure is too high, or it may simply be that the gas valve vent tube is blocked. If the incoming

gas pressure is correct and the vent tube is unobstructed, the gas valve regulator is probably defec-

tive.

6-11

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.

On FBR18A models, the unit will not call for heat unless the controller senses that the unit is full of

water. Sensing is accomplished when the water level in the cookpot contacts the upper water level

sensor, grounding it. If the mineral content of the water is unusually low, such as with distilled, pu-

rified, or highly filtered water, the water will not ground the sensor. If this is the cause, adding ap-

proximately ⅛-cup of salt to the water will usually solve the problem.

Similarly, if the upper water level sensor becomes encrusted with lime, starch, or some other build-

up, it will not ground properly. The solution is to clean the water level sensors thoroughly with a

Scotchbrite™ or similar nylon scouring pad.

6.8

Troubleshooting Guides

The troubleshooting guides found in the pages that follow are intended to assist service technicians

in quickly isolating the probable causes of equipment malfunctions by following a logical, step-by-

step process. An additional set of operator troubleshooting guides is contained in Chapter 5. It is

suggested that service technicians thoroughly familiarize themselves with both sets.

6-12

6.8.1 Troubleshooting the Gas Valve

NOTE: All voltage measurements

must be made within 4 seconds of

unit calling for heat. If unit does

not fire within 4 seconds, ignition

modules will lock out and

MAIN GAS SUPPLY

VALVE VERIFIED TO BE

OPEN AND EQUIPMENT GAS

VALVE IN ON POSITION.

controller must be turned off then

back on to reset.

Problem is with

24VAC circuit. Refer to

Troubleshooting the

24VAC Circuit.

Is there 24VAC

on gas valve main coil (PV

terminal)?

Yes

What gas is the

unit configured for?

LP (Propane)

Gas

Natual Gas

Is incoming

gas pressure 6-14"

W.C. (1.49-3.49

kPa)?

Is incoming

gas pressure 11-14"

W.C. (2.74-3.49

kPa)?

Problem is with gas

supply to fryer.

Yes

Adjust pressure to

specification. If gas valve

will not adjust, replace gas

valve.

Is burner manifold

gas pressure 3.5" W.C.

(0.8 kPa)?

Is burner manifold

gas pressure 8.25" W.C.

(2.5 kPa)?

Yes

Is gas valve vent tube

obstructed?

Is gas Valve vent tube

obstructed?

Yes

Clear obstruction.

Problem is not with

gas valve.

6-13

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).

NOTE: All voltage measurements must

be made within 4 seconds of unit

calling for heat. If unit does not fire

within 4 seconds, ignition modules will

lock out and controller must be turned

off then back on to reset.

Is 24VAC

Is 24VAC present on

interface board J3 pin 9

(LED 5 (GV) lit)?

Yes

present across the gas

valve main coil (PV

terminal)?

Yes

24V circuit is

OK.

Probable cause is

failed wire between

interface board and gas

valve.

Probable causes are failed

24V transformer or failed

wiring between transformer

and interface board.

Is LED 3 (24V) lit

continuously?

Yes

Is 24VAC

present on 25V terminal

of LEFT ignition

module?

Is LED 4

(PWR) lit?

Yes

Is LED 2

(PWR) lit?

Yes

Check for 12VDC across interface

board J2 pins 4 & 5 when controller is calling

for heat. If 12VDC is not present, probable

causes are failed controller or failed relay on

interface board. On later design boards, relay K3

may be replaced. On earlier design boards,

the entire interface board must be

Is 24VAC

present on 25V terminal

of RIGHT ignition

module?

Is 24VAC

present on VALVE

terminal of ignition

module?

Probable cause is

failed wiring harness.

Yes

replaced..

Probable causes are failed

wiring between blower centrifugal

switch and module, failed centrifugal

switch, or failed wiring harness.

If fuse is not blown,

module has failed.

6-14

THE 24 VAC CIRCUIT IN FBR18 UNITS

24V

TRANSFORMER

J3 PIN 8

LED

3 (24V)

RELAY K2 ON EARLY DESIGN BOARDS

RELAY K3 ON LATER DESIGN BOARDS

LED

4 (PWR)

RIGHT PWR TERMINAL

J2 PIN 7

BLOWER

CENTRIFUGAL

SWITCH

RIGHT

IGNITION

MODULE

J2 PIN 5

V1S TERMINAL

LED

2 (PWR)

LEFT PWR TERMINAL

J2 PIN 2

LEFT

IGNITION

MODULE

J2 PIN 4

V2S TERMINAL

LED

5 (GV)

J3 PIN 9

GAS

VALVE

6-15

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?

Go to

"A".

Yes

Ensure upper water level

sensor is not grounded (i.e., 24VAC

present across sensor and cabinet). If

sensor is not grounded, most

probable cause is failed

Is WATER

LED lit?

interface board.

Yes

Most probable cause is

a failed solenoid, but may

also be a failed water relay on

interface board or failed

interface board.

Is unit filling

with water?

Yes

Once water

reaches upper water

level sensor, does filling stop

and WATER LED

go out?

Most probable cause

is failed solenoid, but may

also be a failed water relay

on interface board.

Is WATER

LED lit?

Yes

Most probable cause is dirty upper

water level sensor, but could also be a

loose connection between sensor and

interface board, or a failed interface

board.

Water leg of 24V

circuit is OK.

6-16

6.8.3 Troubleshooting the 24 VAC Circuit in FBRA18 Units (Continued)

NOTE: All voltage measurements involving the

gas valve leg of the 24V circuit must be made

within 4 seconds of unit calling for heat. If unit

does not fire within 4 seconds, ignition modules

will lock out and controller must be turned off

then back on to reset.

Is 24VAC

present on N/O

terminal of latch

relay?

Probable causes are failed

24V transformer or failed wiring

between transformer box and

component box.

Yes

If 12VDC is applied across coil,

probable cause is failed relay. If not,

probable cause is failed wiring between

controller and latch relay or failed

controller.

Is 24VAC

present on COM

terminal of latch

relay?

Yes

Probable causes are failed

wiring between terminal block

and computer, or failed

computer.

Is 24VAC

present on J1 pin

Yes

When water level

is above lower water level

sensor, is CYCLE LED lit?

Go to

"C".

Yes

Go to

"B".

6-17

6.8.3 Troubleshooting the 24 VAC Circuit in FBRA18 Units (Continued)

NOTE: All voltage measurements involving the

gas valve leg of the 24V circuit must be made

within 4 seconds of unit calling for heat. If unit

does not fire within 4 seconds, ignition

modules will lock out and controller must be

turned off then back on to reset.

Is 24VAC

present across the gas

Gas valve leg

of 24V circuit is

Yes

valve main coil (PV)

OK.

terminal?

Probable cause is

failed wiring between

24VAC present on

VALVE terminal of LEFT

module and gas valve.

ignition module?

Yes

Is 24VAC present

on 25V terminal of LEFT

ignition module?

If fuse is not

blown, module

has failed.

Yes

Is 24VAC

present on J2

pin 4?

Is 24VAC present

on 25V terminal of RIGHT

ignition module?

24VAC present on

VALVE terminal of RIGHT

ignition module?

Yes

Probable causes are failed

wiring between blower centrifugal

switch and module, failed

centrifugal switch, or failed

wiring harness.

Probable cause

is failed wiring

harness.

Is 24VAC

present on J2

pin 3?

Probable cause

is failed CYCLE

relay.

Yes

Probable cause is

failed wiring between

terminal block and J2

pin 3.

6-18

6.8.3 Troubleshooting the 24 VAC Circuit in FBRA18 Units (Continued)

NOTE: All voltage measurements must be

made within 4 seconds of unit calling for

heat. If unit does not fire within 4 seconds,

ignition modules will lock out and controller

must be turned off then back on to reset.

Is 24VAC

Probable cause

is failed interface

board.

present on J1 pin 5

when unit calls for

heat?

Is J1 pin 2

grounded?

Yes

Clean lower water

level sensor and

ground it.

Does

CYCLE LED light

when unit calls for

heat?

Yes

Go to

"B".

Is 24VAC

present on COM

terminal of 12VDC relay

when unit calls for

heat?

Is 24VAC

present on N/O

terminal of 12VDC

relay?

Probable cause is

failed wiring between

relay and interface

board.

Yes

Probable cause is

failed wiring between

latch relay and 12VDC

relay.

12VDC present

Probable cause

is failed 12VDC

relay.

Yes

across coil of 12VDC relay

when unit calls for

heat?

Probable cause is

failed controller wiring

harness or failed

controller.

6-19

THE 24VAC CIRCUIT IN FBRA18 UNITS

CONTROLLER

24V

TRANSFORMER

12VDC

RELAY

LATCH

RELAY

J2 PIN 2

J1 PIN 3

J2 PIN 3

LED

POWER

INTERFACE BOARD

LOGIC CIRCUITRY

J1 PIN 5

LED

WATER

CYCLE

WATER

RELAY

CYCLE

RELAY

J2 PIN 1

J2 PIN 4

INTERFACE BOARD

BLOWER

CENTRIFUGAL

SWITCH

WATER

SOLENOID

VALVE

RIGHT

IGNITION

MODULE

WIRING HARNESS PIN 5

WIRING HARNESS PIN 2

LEFT

IGNITION

MODULE

WIRING HARNESS PIN 4

GAS

VALVE

6-20

6.8.4 Troubleshooting the Temperature Probe

WHILE IT IS STILL IN

THE COOKPOT,

INSPECT THE PROBE

BODY FOR DAMAGE.

REPLACE IF BENT,

DENTED, OR CRACKED.

Inspect leads for

fraying, burning,

breaks, and/or kinks. If

found, replace probe.

Determine temperature

of water in cookpot

using a thermometer or

pyrometer placed at tip

of probe.

Is resistance

approximately equal to that

given in the Probe Resistance

Chart for the corresponding

temperature?

Yes

Measure resistance

through each of the

previously tested pins

to ground.

Is resistance

5 megaohms or greater

in each pin?

Probe has failed.

Yes

Probe is good.

6-21

Probe Resistance Chart

OHMS

1000

1002

1004

1006

1008

1011

1013

1015

1017

1019

1021

1023

1025

1030

1032

1034

1036

1038

1040

1042

1044

1046

1049

1051

1053

1055

1057

1059

1061

1063

1065

1067

1068

1070

1072

1074

1076

1078

1080

1082

1084

1086

1089

1091

1093

1095

1097

1099

1101

1103

1105

OHMS

1107

1110

1112

1114

1116

1118

1120

1122

1124

1126

1128

1131

1133

1135

1137

1139

1141

1143

1145

1147

1149

1151

1154

1156

1158

1160

1162

1164

1166

1168

1170

1172

1174

1176

1179

1181

1183

1185

1187

1189

1191

1193

1195

1197

1199

1201

1204

1206

1208

1210

1212

OHMS

1214

1216

1218

1220

1222

1224

1226

1229

1231

1233

1235

1237

1239

1241

1243

1245

1247

1249

1251

1253

1255

1258

1260

1262

1264

1266

1268

1270

1272

1274

1276

1278

1280

1282

1284

1287

1289

1291

1293

1295

1297

1299

1301

1303

1305

1307

1309

1311

1313

1315

1317

OHMS

1320

1322

1324

1326

1328

1330

1332

1334

1336

1338

1340

1342

1344

1346

1348

1350

1352

1354

1357

1359

1361

1363

1365

1367

1369

1371

1373

1375

1377

1379

1381

1383

1385

1387

1389

1391

1393

1395

1398

1400

1402

1404

1406

1408

1410

1412

1414

1416

1418

1420

1422

OHMS

1424

1426

1428

1430

1432

1434

1436

1438

1440

1442

1444

1447

1449

1451

1453

1455

1457

1459

1461

1463

1465

1467

1469

1471

1473

1475

1477

1479

1481

1483

1485

1487

1489

1491

1493

1495

1497

1499

1501

1503

1505

1507

1509

1512

1514

1516

1518

1520

1522

1524

1526

134

135

136

137

138

139

140

141

142

143

144

145

146

147

148

149

150

151

152

153

154

155

156

157

158

159

160

161

162

163

164

165

166

167

168

169

170

171

172

173

174

175

176

177

178

179

180

181

182

183

184

185

186

187

188

189

190

191

192

193

194

195

196

197

198

199

200

201

202

203

204

205

206

207

208

209

210

211

212

213

214

215

216

217

218

219

220

221

222

223

224

225

226

227

228

229

230

231

232

233

234

235

236

237

238

239

240

241

242

243

244

245

246

247

248

249

250

251

252

253

254

255

256

257

258

259

260

261

262

263

264

265

266

267

268

269

270

271

272

273

274

275

276

277

278

279

280

281

282

283

284

285

286

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

141

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

100

101

102

103

104

105

106

107

108

109

110

111

112

113

6-22

6.9

Wiring Diagram for FBR18 Units

N C

N O

N C

C A B L E

L T A G E G H H I V O

D U O L M

N O I T I N I G

N O I T I

I G

R )

U R ( B N E

G N

R )

U R ( B N E

G N

2 5 V

E V L V A

A R A L

E V L V A

A R A L

)

D N ( G

)

D N ( G

2 5 V

1 9

6-23

6.10 Wiring Diagram for FBRA18 Units

N C

O N /

C O

O N /

C O

1 2 1 1

1 0

A C B K L

E T W H I

6-24

FBR18 & FBRA18 SERIES GAS RETHERMALIZERS

CHAPTER 7: PARTS LIST

7.1

Burner System Components

ITEM

PART #

COMPONENT

Burner Assemblies

806-5563

806-5564SP

Natural Gas, Complete

Propane Gas, Complete

810-1382 Burner, Reverse Plenum, Universal

Orifice

810-0916

810-0917

Natural Gas, 3.26mm

Propane Gas, 2.00mm

Ignitor

810-0521

810-0608

807-1564

823-2528

900-5525

816-0055

810-0507

807-1878

816-0165

806-5541

816-0278

823-2526

823-2685

900-1789

Natural Gas

Propane Gas

Blower, Combustion Air

Mount, Combustion Air Blower

Bracket, Combustion Air Blower Stabilizer

Insulation, Burner Support, ½” x 17.38”

Spacer, Combustion Air Blower Mount, .23” x .75”

Ignitor Wire, 19” (See illustration on Page 7-3)

Insulation, Ignitor

Flame Sensor Wire (See illustration on Page 7-3)

Hose, Air, ⅝” ID

Bracket, Air Hose Connection, Left

Bracket, Air Hose Connection, Right

Enrichment Tube

* Not illustrated

7-1

7.2

Cabinetry and Associated Components

ITEM

PART #

910-1181

816-0157

900-4603

823-2107

810-2263

910-7434

900-7379

900-7377

900-4521

812-1141

900-1552

900-4505

900-1759

900-7376

900-4504

COMPONENT

Retainer, Flue Cap Insulation

Insulation, Flue

Flue Guard

Flue Cap

Hanger, Basket (810-2263 hanger replaced extruded aluminum hanger, which is no longer available.)

Top Cap

Back, Cabinet

Side, Cabinet, CRS, Left or Right

Retainer, Cabinet Back Insulation

Insulation, Cabinet Back

Gusset

Top Brace

Bracket, Pot Hold Down

Channel, Base Side, Left or Right

Channel, Base Front or Rear

806-3853 Door Assembly

810-1422 Handle, Wireform Door

826-3811

810-0356

810-0357 Caster, 5-inch Wheel, w/Brake

826-0900 Chain Restraint Kit

806-5209

812-1142

Leg Assembly (set of four)

Caster, 5-inch Wheel, w/o Brake

Leg Pad Assembly

Insulation, Cabinet Back, 2” x 17.5”

7-2

ITEM

PART #

COMPONENT

* Not illustrated

7.3

Control Box Assembly and Associated Parts, FBR18/ FBRA18

R )

U B R ( N E

G N

R )

U B R ( N E

G N

2 5

L V V A

A R A M L

L V V A

A R A L

)

D N ( G

N D G ( )

2 5

LEFT

RIGHT

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

COMPONENT

807-1706

Cable, Ignition, 36-inch

806-5541 Wire, Flame Sensor

807-0855 Transformer, 120V-12V, 20VA, 50/60 Hz

807-0800 Transformer, 120V-24V, 50VA, 50/60 Hz

807-0067 Block, 8-pin Terminal

810-0045 Bushing, .875-inch

806-5332 Cord, Electrical Power

900-4508 Control Box Heat Shield

900-4510 Control Box Side

806-9334 Harness, 12-pin Wiring

806-9335 Harness, 9-pin Wiring

* Not illustrated.

7-3

7.4

Controller and Component Box Assemblies

SOUND

FBR18

GND

Component Box

GND

V2D

PWR

A D

A S

V2S

V1D

PWR

ALRM

V1S

GND

- - - -

Frymaster

Controller

FBRA18

Component Box

ITEM

PART #

COMPONENT

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)

806-5303

Controller, Digital (used on FBR18 and FBRA18)

806-9414 Control Box Assembly (used on FBRA18 only)

806-9592 Interface Board (used on FBRA18 only)

807-1683 Relay, 12VDC (used on FBRA18 only)

807-0067 Block, 8-pin Terminal

807-1241 Spacer, Interface Board Standoff, ⅝-inch (used on FBRA18 only)

* Not illustrated.

7-4

7.5

Cooking Timer Control Panel Components

Error! Not a valid link.

ITEM

PART #

COMPONENT

910-4496 Cooking Timer Control Panel

Knob Assembly

810-1287

806-5339

806-5340

806-5341

806-5342

806-5343

Black

Gray

Red

Brown

Blue

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

7-5

7.6

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

COMPONENT

810-0809 Block, Probe Mounting

816-0157 Insulation, Upper Flue, 8.5” x 18.0”

816-0158 Insulation, Lower Flue, 10.5” x 19.0”

816-0055

Insulation, Burner Support, ½” x 17.38”

816-0145 Insulation, Bottom Front, 3.0” x 14.5”

816-0166 Insulation, Bottom Rear, 3.5” x 17.0”

809-0204 Washer, Teflon, ⅝” x 1”

* Not illustrated.

7-6

7.7

Cookpot, FBRA18

This washer must be

seated in hole before

nut is tightened.

Inside face of

cookpot.

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

COMPONENT

813-0557 Elbow, Plastic, 1” NPT to 1” Barb

816-0144 Insulation, Cookpot Side

806-7552SP Sensor Assembly, Upper or Lower Water Level

910-5196 Cover, Water Level Sensors

806-5251 Probe Assembly, Temperature

824-0395 Guard, Probe

900-1031 Retainer, Sight Glass

816-0053 Insulation, Sight Glass

814-0048 Sight Glass

810-0809 Block, Teflon, Probe Mounting

816-0157 Insulation, Upper Flue, 8.5” x 18.0”

816-0158 Insulation, Lower Flue, 10.5” x 19.0”

816-0145 Insulation, Bottom Front, 3.0” x 14.5”

816-0166 Insulation, Bottom Rear, 3.5” x 17.0”

809-0204 Washer, Teflon, ⅝” x 1”

816-0055 Insulation, Burner Support, ½” x 17.38”

* Not illustrated.

7-7

7.8

Gas Supply Components

ITEM

PART #

COMPONENT

Gas Valve

Natural Gas

LP (Propane) Gas

810-0786

810-0787

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” NPT x 90°, BM

813-0433 Nipple, ⅛” NPT x 2 ½”, BM

813-0304 Bushing, ½” x ¼” Flush, BM

813-0301 Tee, Male, ⅜” x ¼” NPT x ⅜”, Brass

813-0022 Nipple, ½” NPT Close, BM

813-0062

813-0265

823-2766

813-0257

823-1893

810-0816

Elbow, ½” x 90°, BM

Nipple, ½” NPT x 2 ½”, BM

Mounting Bracket, Gas Line

Nipple, ¾” NPT x 24 ½”, BM

Bracket, Rear Manifold

Plug, Honeywell Gas Valve

* Not illustrated.

7-8

7.9

Plumbing Components

ITEM

PART #

806-9067 Valve Assembly, Solenoid (FBRA18 only)

810-1208 Valve, Water Pressure Regulator (FBRA18 only)

COMPONENT

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 Compression Fitting, Straight, ¼” (FBRA18 only)

813-0022 Nipple, ½” x Close, BM NPT (FBRA18 only)

910-8026 Tubing, SS, Water Line (FBRA18 only)

813-0471 Nipple, ¼” x 1½” Brass NPT (FBRA18 only)

806-8467SP Valve Assembly, Drain w/Microswitch, Complete (FBR18 only)

807-2103 Microswitch (FBR18 and FBRA18)

813-0379 Elbow, Street, 1 ¼” BM NPT (FBR18 only)

810-1020 Valve, Drain (FBRA18 only)

823-2047 Handle, Drain Valve (FBRA18 only)

816-0371 Hose, Drain (FBRA18 only)

813-0314 Tee, 1” BM NPT (FBRA18 only)

813-0138 Nipple, 1” BM NPT (FBRA18 only)

813-0202

Elbow, 1” x 90° BM NPT (FBRA18 only)

813-0525 Fitting, Barbed, 1” NPT to Hose (FBRA18 only)

7-9

7-10

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

1-800-551-8633

819-5278

May 2003

PRINTED IN THE UNITED STATES

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