FBCR18 & FBKR18 Series Gas Rethermalizers Installation, Operation, Service, and Parts Manual Frymaster, a member of the Commercial Food Equipment Service Association, recommends using CFESA Certified Technicians.
NOTICE IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART FOR THIS ENODIS EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART PURCHASED DIRECTLY FROM FRYMASTER/DEAN, OR ANY OF ITS AUTHORIZED SERVICE CENTERS, AND/OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL CONFIGURATION, THIS WARRANTY WILL BE VOID.
FBCR18 & FBKR18 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.
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 .........................................
FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS CHAPTER 1: GENERAL INFORMATION 1.1 Applicability and Validity This manual is applicable to and valid for all FBCR18 and FBKR18 units sold in Englishspeaking countries. Where conflicts exist between instructions and information in this manual and local or national codes of the country in which the equipment is installed, installation and operation shall comply with those codes.
1.3 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 one below. 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.
1.6 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.
FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS CHAPTER 2: INSTALLATION INSTRUCTIONS 2.1 General Installation Requirements Qualified, licensed, and/or authorized installation or service personnel, as defined in Section 1.6 of this manual, should perform all installation and service on Frymaster equipment. Conversion of this appliance from one type of gas to another should only be performed by qualified, licensed, and/or authorized installation or service personnel as defined in Section 1.6 of this manual.
One of the most important considerations of efficient operation is ventilation. Make sure the equipment is installed so that products of combustion are removed efficiently, and that the kitchen ventilation 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.
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 inside of the door for proper voltages.
2. The rethermalizer must be stabilized by installing restraining chains on units equipped with casters or anchor straps on units equipped with legs. Follow the instructions shipped with the casters/legs to properly install the chains or straps. 3. Level rethermalizers equipped with legs by screwing out the legs approximately 1 inch then adjusting them so that the rethermalizer is level. 4. For rethermalizers equipped with casters, there are no built-in leveling devices.
2.4 Connecting to the Gas Supply DANGER Before connecting new pipe to this appliance, the pipe must be blown out thoroughly to remove all foreign material. Foreign material in the burner and gas controls will cause improper and dangerous operation. DANGER When pressure-testing incoming gas supply lines, disconnect the appliance from the gas line if the test pressure will be ½ PSIG (3.45 kPa, 13.84 inches W.C.) or greater to avoid damage to the appliance’s gas tubes and gas valve(s).
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. 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. 4.
FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS CHAPTER 3: OPERATING INSTRUCTIONS 3.1 Introduction WARNING The on-site supervisor is responsible for ensuring that operators are made aware of the inherent hazards of operating a gas-fired heated water system, particularly the aspects of draining and cleaning procedures. Mechanically, the FBCR18 and FBKR18 rethermalizers are virtually identical. The FBKR18 units have a manual fill switch in addition to the AutoFill feature.
PROGRAMMING THE FBCR18 SERIES COMPUTER switch. 1. Turn the computer on by pressing the Power 2. Press the Program Mode switch. CodE appears in the left display. Press, in sequence, product buttons 1, 6, 5, and 10. (Press switch again to exit the programming mode.) NOTE 1: The programming mode is not available while the computer is rethermalizing; the display will flash BUSY.
If you rethermalize more food than you use, use the chill feature to quickly reduce the temperature of the food before refrigerating or freezing. 1. Press the Chill Mode switch to de-energize the heating elements. 2. Open the drain valve and drain most of the hot water. The AutoFill will refill the cookpot with cold water. If desired, add ice to the cookpot to accelerate the cooling process. 3. Remove the product bags when cooled and return them to the refrigerator or freezer.
Pressing the Boil Mode (L) switch overrides the programmed setpoint and the cookpot temperature rises to boiling at 212°F (100°C). When the unit is in boil mode, boiL appears in both LED displays. The unit remains in boil mode until the Simmer Mode switch is pressed or the unit is turned off. Pressing the Simmer Mode (R) switch causes the cookpot temperature to be maintained at the programmed setpoint. If the cookpot temperature is above the setpoint, °-HI is displayed in both LED widows.
NOTE 1: Programming mode is not available while the computer is rethermalizing; the display will flash BUSY. NOTE 2: To toggle between Fahrenheit and Celsius temperature display, press the Program Mode switch, then enter the code 1 6 5 8 by pressing the corresponding product buttons. Next, press the Temperature Check/Program Lock switch to lock in the new display option. 3. Enter the number 1 6 5 0 by pressing the corresponding product buttons. Unless this code is entered, programming will not be accepted.
Remember: Stir time 2 must be greater than stir time 1 (or else be “0”). Stir time 3 must be greater than stir time 2 (or else be “0”). None of the stir times should be greater than the rethermalizing time entered in Step 6. If a stir time exceeds the rethermalizing time, the stir alarm will not sound. 8. SELP (Select Product) again appears in the left display. Return to Step 5 and follow all instructions to program more products. 9.
To change the temperature display, press the Program Mode display. switch; CodE appears in the To toggle constant temperature display on and off, enter 1, 6, 5, 1, . NOTE: When in constant temperature display mode, the countdown time will not be displayed. To toggle between Fahrenheit and Celsius temperature display, enter 1, 6, 5, 8, . FBKR18 COMPUTER DISPLAY MESSAGES SELP – Prompts you to select a product button for programming. CodE – Prompts you to enter a sequence of numbers to change functions.
3.4 Start-Up Procedure (Applies to both the FBCR18 and FBKR18) WARNING Never operate this appliance with an empty cookpot. The cookpot must be filled with water before lighting the burners. CAUTION If this is the first time the unit is being used after installation, refer to Section 3.5, Boiling-Out the Cookpot.
3.5 Boiling-Out the Cookpot DANGER Never leave the appliance unattended during the boil-out process. If the boil-out solution boils over, turn the appliance off immediately and let the solution cool for a few minutes before resuming the process. To lessen the chance of boil over, turn the appliance’s gas valve knob to the PILOT position occasionally.
FBCR18 & FBKR18 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.
4.2 Quarterly Checks and Services Check Computer Magic III Set Point Accuracy 1. Fill the cookpot with water. Press the computer power switch, and then press any of the product buttons. Insert a good-grade thermometer or pyrometer probe into the cookpot, with the end touching the temperature probe at the lower right front of the cookpot. switch once to 2. When the computer display shows a series of four dashes (- - - -), press the display the temperature of the water as sensed by the temperature probe.
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. Vent Tube 3. Pass a piece of ordinary binding wire (.052 inch diameter) through the tube to remove any obstruction. 4.
3. Place the gas valve in the ON position. Place the computer power switch in the ON position. When the burner lights and continues to burn, compare the indicated pressure to the table below. Burner Manifold Gas Pressures Gas Natural LP Pressure 3.5" W.C. 0.8 kPa 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.
FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS CHAPTER 5: OPERATOR TROUBLESHOOTING 5.1 Introduction DANGER Water heated to cooking/rethermalizing temperature will cause severe burns. Never attempt to move this appliance when filled with heated water or to transfer heated water from one container to another. DANGER This equipment should be unplugged when servicing, except when electrical circuit tests are required. Use extreme care when performing such tests.
5.2 Troubleshooting Guides COOKPOT DID NOT FILL WHEN UNIT WAS TURNED ON. WATER SUPPLY TO UNIT VERIFIED TO BE ON. Computer is not functioning. Probable causes are failed 12V transformer, failed interface board, or failed computer. Did anything appear in CM III display when unit was turned on? No Yes Open control panel by removing screws in upper corners. Is WATER LED on interface board illuminated? No Yes Use bottle brush to clean water level sensors.
WATER NOT HEATING. AUTOFILL WORKED PROPERLY. Press the Temperature Check button twice to display setpoint. Is the displayed setpoint correct? No Enter correct setpoint in accordance with instructions in Chapter 3. Yes Did burners light? No Refer to troubleshooting guide "BURNERS DO NOT LIGHT". No Insert a good grade thermometer into cookpot with tip near the temperature probe and wait two minutes. Press the Temperature Check button once to display the cookpot temperature.
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? Yes Problem resolved. Yes Problem resolved. Yes Problem is with the gas supply or ignition system. Call FASC. No Use bottle brush to clean low water sensor. If burners still do not light, remove the cover over the water sensors and thoroughly clean them with a scouring pad.
CM III WILL NOT GO INTO PROGRAMMING MODE OR DOES NOT ACCEPT CHANGES TO PROGRAM. Press Power Switch OFF, disconnect unit from electrical power, open control panel by removing screws in upper corners, and unplug wiring harness from interface board. Wait two minutes. Reconnect computer wiring harness, close control panel, reconnect unit to electrical power, and press Power Switch ON. Does computer operate properly? Yes Problem resolved.
5.3 Replacing the Computer or Computer 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 computer. If replacing the harness, disconnect it from the interface board, install the new harness, and then reverse steps 1 and 2 to complete the process. 4.
FBCR18 & FBKR18 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 efficiency 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.
Inside the Ignition Module Out to Gas Valve To Alarm 25 V + Coil TD HV 25 V GND Ignition Wire Flame Sensor COMPUTERS These rethermalizers are equipped with Computer Magic III computers that have been modified for this specialized application. Although similar in appearance to standard Computer Magic III computers, the standard CM III computers will not operate the unit correctly. Only part number 806-8063 may be used in FBCR18 units and only part number 806-9352 may be used in FBKR18 units.
solenoid valve when the water level reaches the upper water level sensor and to de-energize the solenoid when the water level drops below the upper water level sensor. The board has four LEDs to assist in troubleshooting. Three of the LEDs (LATCH, WATER, and HEAT) are located just to the right of the heat relay (K4). The fourth LED is not labeled. It is located in the lower left portion of the board, just above a large orange resistor.
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 Cleaning the Gas Valve Vent Tube 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.
6.6.2 Replacing the Temperature Probe 1. Unplug the rethermalizer. 2. Drain the cookpot. 3. 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. 4. Remove the cover from the component box by removing the three screws along its bottom edge. 5. Cut the temperature probe wires an inch or so from the 12-pin connector. Leave the cut off wires in the connector. 6.
10. Reattach the 15-pin connector to the interface board. 11. Close and secure the control panel. 6.6.4 Replacing an Ignition Module 1. Unplug the rethermalizer. 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. Remove the component box cover by removing the three screws along its bottom edge. 4. Remove the wires from the ignition module one at a time and mark them to facilitate reconnection. 5.
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 flexible gas lines at each burner orifice. 4. Disconnect the gas enrichment tubes at the gas valve tee 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.
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 outermost screws on the back.
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. Computer-related problems 5. Autofill System problems. The probable causes of each category are discussed in the following sections. A series of Troubleshooting Guides (decision trees) is also included at the end of the chapter to assist in identifying some of the more common problems. 6.7.
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.
If popping is consistent during all hours of operation, the most likely cause is an insufficient air supply. Check for “negative pressure” conditions in the kitchen area. If air is flowing into the kitchen area, this indicates that more air is being exhausted than is being replenished, and the burners may be starved for air. If the rethermalizer’s gas and air supplies are okay, the problem is most likely with one of the electrical components.
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 interface board, the water level sensors, the computer, and the ignition module. Whatever the cause, the symptom is failure of the unit to attain or maintain setpoint temperature. The unit will not call for heat unless the computer senses that the unit is full of water.
6.8.1 Troubleshooting the Gas Valve MAIN GAS SUPPLY VALVE VERIFIED TO BE OPEN AND EQUIPMENT GAS VALVE IN ON POSITION. Is 24VAC present on the main coil (PV terminal) of the gas valve? No Problem is with the 24VAC circuit. Refer to Troubleshooting the 24VAC Circuit. Yes What gas is the unit configured for? LP (Propane) Natural Is incoming gas pressure 6-14" W.C. (1.49-3.49 kPa)? No Problem is with gas supply to fryer. No Is incoming gas pressure 11-14" W.C. (2.74-3.
6.8.2 Troubleshooting the 24 VAC Circuit WATER LEVEL IN COOKPOT IS ABOVE LOWER WATER LEVEL SENSOR AND COMPUTER IS ACTIVATED. Is 24VAC present on J2 Pin 7? No Probable cause is a failed transformer. No Probable cause is failed computer or failed 15-pin wiring harness.
THE 24VAC CIRCUIT 24V LEG OF DUAL VOLTAGE TRANSFORMER J2 PIN 7 LED K3 K6 WATER K4 HEAT J2 PIN 2 J2 PIN 4 BLOWER CENTRIFUGAL SWITCH WATER SOLENOID VALVE LEFT IGNITION MODULE RIGHT IGNITION MODULE GAS VALVE 6-15
6.8.3 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.
Probe Resistance Chart F OHMS C F OHMS C F OHMS C F OHMS C F OHMS C 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 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 0 1 1 2 2 3 3 4 4 5
Simplified Wiring Diagrams (FBKR18 ONLY) 6.
200-240V BLK 32C 31C WHT GREEN BLUE 1 BROWN LINE 6 TEMP PROBE T2 120 V BLK 22C 24V 12V WHT 23C LOAD HI LEVEL PROBE 27C 6C LINE T1 LO LEVEL PROBE 11C 28C 12C WHT 27C 4C BLK 8C 9C 28C 12 11 10 9 8 7 6 5 4 3 2 1 5C 4C 7C SWITCH 8C 2C 9C BLOWER ORG J3 J5 5C 13C 7C DUAL SPARK IGNITION MODULE 2C 29C 15PIN CABLE TO COMPUTER J4 PIN 1 J2 43C PIN 1 55C 30C BUZZER 16C PIN 1 16C J1 IGNITOR CABLE RIGHT INTERFACE BOARD IGNITOR CABLE RIGHT IGNITOR LEFT HIGH TEMP WIRE LEFT H
6-20 SOUND DEVICE 120VAC IN 1 12 4 2 7 3 9 10 11 J2 10 Q3 ALARM WATER K6 WATER 24VAC COMPUTER 11 J4 24V INTERFACE BOARD 806-9295 1 K4 HEAT HEAT 3 ON/OFF 5 K3 LATCH 24VAC LATCH 4 J3 Q2 U2B U2A LOW WATER SENSOR K5 14 J5 13 U2C U2D 24VAC HIGH WATER SENSOR J1 6 8 LEFT PRODUCT BUTTONS 9 K2 RIGHT PRODUCT BUTTONS 7 K1 OPTIONAL BASKET LIFTS DN UP COM UP DN 5 4 1 2 3 Part of J2 TEMPERATURE PROBE
FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS CHAPTER 7: PARTS LIST 7.1 Burner System Components 5 1 2 3 4 ITEM PART # COMPONENT Burner Assemblies 806-5563 Natural Gas, Complete 806-5564SP Propane Gas, Complete 1 810-1382 Burner, Reverse Plenum, Universal 2 Orifice 810-0916 Natural Gas, 3.26mm 810-0917 Propane Gas, 2.
7.2 Cabinetry and Associated Components 3 5 4 18 8 9 6 1 19 10 2 7 11 17 12 20 13 16 14 ITEM PART # 1 806-8060 2 810-1374 3 910-5246 4 910-5303 5 823-2881 6 900-5737 7 900-7377 8 900-5293 9 816-0158 10 900-4521 11 812-1141 12 900-1552 13 900-4505 14 900-7376 15 900-4504 16 806-3853 17 810-1442 18 810-0356 19 810-0357 20 826-0900 * 826-1095 * 824-0606 * 806-5209 * 826-1043 * 806-3811 * 910-8403 * Not illustrated.
7.3 Computer, Component Box Assembly, and Associated Parts 6 4 INTERFACE BOARD MOUNTS ON THESE STUDS 3 1 5 2 NOTE: Components are not drawn to scale relative to each other. 7C 29C Pin 1 7 2C 8 8C 5C 4C 9C ITEM PART # * 106-0769 * 806-9352 * 806-9295 * 807-0154 * 809-0349 * 809-0446 1 807-2176 2 807-1006 3 807-2659 4 807-1713 5 806-4797 6 810-1164 7 806-9286 8 806-2071 * Not illustrated.
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7.6 Plumbing Components 3 2 4 5 8 6 7 NOTE: Valve handle nut comes with valve. 1 18 17 16 10 15 13 14 12 19 9 11 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PART # 810-1208 810-1351 813-0448 813-0473 813-0471 900-2916 810-1025 900-5210 806-5565 910-5228 810-1372 813-0202 813-0314 813-0525 809-0374 810-1824 910-9527 816-0372 813-0138 COMPONENT Valve, Water Pressure Regulator Vacuum Breaker Elbow, ¼”, Brass Nipple, ¼” x 4.0”, Brass Nipple, ¼” x 1.
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 PRINTED IN THE UNITED STATES FAX (Tech Support) 1-318-219-7135 SERVICE HOTLINE 1-800-551-8633 Price: $10.
