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  
i
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  
ii  
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  
LP  
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  
C
9 . 9  
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  
LP  
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.  
No  
Yes  
Open control panel by  
removing screws in  
each upper corner.  
Is WATER  
LED on interface board  
illuminated?  
Yes  
No  
Use bottlebrush to  
clean water level  
sensors.  
Probable causes are a failed  
interface board or  
Did LED  
No  
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  
No  
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  
No  
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  
No  
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  
No  
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?  
No  
Yes  
Refer to troubleshooting  
guide "BURNERS DO NOT  
LIGHT".  
Did burners  
light?  
No  
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?  
No  
Yes  
Is temperature  
displayed reasonably  
close to thermometer  
reading?  
There is a problem in  
temperature probe  
circuit. Call FASC.  
Problem  
resolved.  
No  
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  
No  
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  
No  
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  
No  
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  
TD  
enrichment tube, and a flame sensor.  
HV  
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  
J2  
1
13  
14  
15  
1
2
4
5
7
8
10  
11  
1
13  
14  
15  
1
2
4
5
7
8
10  
11  
D7  
2
3
2
3
J2  
D6  
GND  
GND  
J1  
3
6
9
12  
3
6
9
12  
AIR  
J3  
12V  
3
2
6
5
9
8
12  
11  
3
2
6
5
9
8
12  
11  
3
2
1
6
5
4
9
8
7
12  
11  
10  
3
2
1
6
5
4
9
8
7
12  
11  
10  
J1  
J3  
1
4
7
10  
1
4
7
10  
K3 K4  
K5  
D1  
K1  
GV  
D5  
GV  
GND  
V2D  
PWR  
AD  
GND  
V1D  
PWR  
ALR  
V1S  
GND  
V2D  
Blower  
Motor  
2 Amp  
BLOWER  
MOTOR  
RELAY  
NOT  
USED  
NOT  
NOT  
USED  
NOT  
USED  
GND  
V1D  
USED  
K4  
PWR  
D3  
PWR  
AD  
AS  
HEAT  
RELAY  
AND  
BLOWER  
MOTOR  
RELAY  
NOT  
USED  
HEAT  
ALR  
V1S  
AS  
24V  
RELAY  
4
PWR  
D2  
NOT  
USED  
D4  
V2S  
V2S  
PWR  
GND  
K1  
K2  
3
1
2
6
5
GND  
K2  
K3  
GND  
GV PWR  
PWR  
GND  
AL 12V AIR 24V AL  
GV  
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.  
J2  
1
K1  
K2  
K3  
HEAT  
WATER  
BLOWER  
J3  
1
J1  
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  
LP  
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 -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)?  
No  
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.  
No  
No  
Yes  
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)?  
No  
No  
Yes  
Yes  
Is gas valve vent tube  
obstructed?  
Is gas Valve vent tube  
obstructed?  
Yes  
Yes  
Clear obstruction.  
No  
No  
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.  
No  
No  
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?  
No  
Yes  
Is 24VAC  
present on 25V terminal  
of LEFT ignition  
module?  
Is LED 4  
(PWR) lit?  
Yes  
Is LED 2  
(PWR) lit?  
Yes  
No  
No  
No  
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  
Yes  
replaced..  
No  
No  
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  
OR  
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".  
No  
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?  
No  
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?  
No  
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?  
No  
No  
Yes  
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  
A
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.  
No  
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?  
No  
Yes  
Probable causes are failed  
wiring between terminal block  
and computer, or failed  
computer.  
Is 24VAC  
present on J1 pin  
3?  
No  
Yes  
When water level  
is above lower water level  
sensor, is CYCLE LED lit?  
Go to  
"C".  
No  
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  
B
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?  
No  
Is  
Probable cause is  
failed wiring between  
24VAC present on  
VALVE terminal of LEFT  
module and gas valve.  
ignition module?  
Yes  
No  
Is 24VAC present  
on 25V terminal of LEFT  
ignition module?  
If fuse is not  
blown, module  
has failed.  
Yes  
No  
No  
Is  
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  
Yes  
No  
No  
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  
No  
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  
C
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  
Yes  
No  
No  
Clean lower water  
level sensor and  
ground it.  
Does  
CYCLE LED light  
when unit calls for  
heat?  
No  
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  
Yes  
No  
No  
Is  
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?  
No  
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  
LED  
WATER  
CYCLE  
WATER  
RELAY  
K2  
CYCLE  
RELAY  
K1  
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?  
No  
Yes  
Measure resistance  
through each of the  
previously tested pins  
to ground.  
Is resistance  
5 megaohms or greater  
in each pin?  
No  
Probe has failed.  
Yes  
Probe is good.  
6-21  
Probe Resistance Chart  
F
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  
C
0
1
1
2
2
3
3
4
4
5
6
6
7
7
8
8
F
83  
84  
85  
86  
87  
88  
89  
90  
91  
92  
93  
94  
95  
96  
97  
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  
C
F
OHMS  
1214  
1216  
1218  
1220  
1222  
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1226  
1229  
1231  
1233  
1235  
1237  
1239  
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1299  
1301  
1303  
1305  
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1309  
1311  
1313  
1315  
1317  
C
F
OHMS  
1320  
1322  
1324  
1326  
1328  
1330  
1332  
1334  
1336  
1338  
1340  
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1418  
1420  
1422  
C
85  
86  
86  
87  
87  
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90  
91  
91  
92  
92  
93  
93  
94  
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95  
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97  
97  
98  
F
OHMS  
1424  
1426  
1428  
1430  
1432  
1434  
1436  
1438  
1440  
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1444  
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1520  
1522  
1524  
1526  
C
32  
33  
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35  
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38  
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44  
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81  
82  
28  
29  
29  
30  
31  
31  
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32  
33  
33  
34  
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35  
36  
36  
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38  
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40  
41  
41  
42  
42  
43  
43  
44  
44  
45  
46  
46  
47  
47  
48  
48  
49  
49  
50  
51  
51  
52  
52  
53  
53  
54  
54  
55  
56  
56  
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  
57  
57  
58  
58  
59  
59  
60  
61  
61  
62  
62  
63  
63  
64  
64  
65  
66  
66  
67  
67  
68  
68  
69  
69  
70  
71  
71  
72  
72  
73  
73  
74  
74  
75  
76  
76  
77  
77  
78  
78  
79  
79  
80  
81  
81  
82  
82  
83  
83  
84  
84  
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  
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235  
236  
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238  
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240  
241  
242  
243  
244  
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246  
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248  
249  
250  
251  
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257  
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259  
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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  
114  
115  
116  
116  
117  
117  
118  
118  
119  
119  
120  
121  
121  
122  
122  
123  
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124  
124  
125  
126  
126  
127  
127  
128  
128  
129  
129  
130  
131  
131  
132  
132  
133  
133  
134  
134  
135  
136  
136  
137  
137  
138  
138  
139  
139  
140  
141  
141  
98  
99  
9
9
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  
10  
11  
11  
12  
12  
13  
13  
14  
14  
15  
16  
16  
17  
17  
18  
18  
19  
19  
20  
21  
21  
22  
22  
23  
23  
24  
24  
25  
26  
26  
27  
27  
28  
98  
99  
99  
100  
101  
101  
102  
102  
103  
103  
104  
104  
105  
106  
106  
107  
107  
108  
108  
109  
109  
110  
111  
111  
112  
112  
113  
6-22  
6.9  
Wiring Diagram for FBR18 Units  
C
N C  
N O  
C
N O  
N C  
C A B L E  
L T A G E G H H I V O  
E
D U O L M  
E
D U O L M  
N O I T I N I G  
N O I T I  
N
I G  
8
7
6
5
4
3
2
1
R )  
U R ( B N E  
G N  
R )  
U R ( B N E  
G N  
2 5 V  
2 5 V  
D
D
E V L V A  
A R A L  
E V L V A  
A R A L  
)
D N ( G  
)
D N ( G  
M
M
2 5 V  
2 5 V  
5
6
7
8
1 9  
2
3
4
*
*
6-23  
6.10 Wiring Diagram for FBRA18 Units  
N C  
N C  
O N /  
M
C O  
O N /  
M
C O  
1 2 1 1  
1 0  
9
8
7
6
5
4
2
1
3
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  
3
1
2
4
6
5
ITEM  
PART #  
COMPONENT  
Burner Assemblies  
806-5563  
806-5564SP  
Natural Gas, Complete  
Propane Gas, Complete  
1
2
810-1382 Burner, Reverse Plenum, Universal  
Orifice  
810-0916  
810-0917  
Natural Gas, 3.26mm  
Propane Gas, 2.00mm  
3
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  
4
5
6
*
*
*
*
*
*
*
*
*
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, ” ID  
Bracket, Air Hose Connection, Left  
Bracket, Air Hose Connection, Right  
Enrichment Tube  
* Not illustrated  
7-1  
7.2  
Cabinetry and Associated Components  
1
3
18  
19  
2
4
12  
5
7
6
9
17  
10  
13  
20  
21  
11  
8
16  
15  
14  
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  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
*
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  
7
6
9
8
7
6
5
4
3
2
1
2
8
10  
R )  
U B R ( N E  
G N  
R )  
U B R ( N E  
G N  
V
2 5  
V
2 5  
2 5  
D
D
E
L V V A  
A R A M L  
E
L V V A  
A R A L  
)
D N ( G  
N D G ( )  
M
V
2 5  
V
2
LEFT  
RIGHT  
3
GREEN  
9
1
4
4
5
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  
1
2
3
4
807-1706  
Cable, Ignition, 36-inch  
5
806-5541 Wire, Flame Sensor  
6
7
8
9
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  
10  
*
*
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  
1
GND  
2
3
Component Box  
1
2
3
4
5
7
8
9
10  
11  
12  
1
2
3
4
5
6
7
8
9
10  
11  
12  
3
6
1
2
J3  
J1  
GND  
GND  
V2D  
PWR  
A D  
A S  
V2S  
V1D  
PWR  
ALRM  
V1S  
GND  
GND  
C
- - - -  
F
Frymaster  
4
Controller  
5
FBRA18  
Component Box  
3
6
8
7
ITEM  
PART #  
COMPONENT  
1
2
*
3
4
5
6
7
8
*
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, -inch (used on FBRA18 only)  
* Not illustrated.  
7-4  
7.5  
Cooking Timer Control Panel Components  
Error! Not a valid link.  
ITEM  
PART #  
COMPONENT  
1
2
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  
3
4
5
6
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  
4
7
6
3
2
1
5
10  
9
8
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  
1
2
3
4
5
6
7
8
9
10  
*
*
*
*
*
*
*
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, ” x 1”  
* Not illustrated.  
7-6  
7.7  
Cookpot, FBRA18  
This washer must be  
seated in hole before  
nut is tightened.  
8
7
Inside face of  
cookpot.  
Torque nut to  
30 in-lb ± 5.  
10  
9
4
5
Enlarged View of Water  
Level Sensor Assembly  
3
2
1
6
13  
12  
11  
ITEM  
PART #  
900-1762 Retainer, Insulation  
900-7431 Cover, Cookpot Front Insulation  
816-0143 Insulation, Cookpot Front  
823-4094SP Cookpot  
COMPONENT  
1
2
3
4
5
6
813-0557 Elbow, Plastic, 1” NPT to 1” Barb  
816-0144 Insulation, Cookpot Side  
7
8
9
10  
11  
12  
13  
*
*
*
*
*
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, ” x 1”  
*
*
816-0055 Insulation, Burner Support, ½” x 17.38”  
* Not illustrated.  
7-7  
7.8  
Gas Supply Components  
7
8
6
5
4
9
3
2
1
10  
15  
14  
11  
13  
12  
ITEM  
PART #  
COMPONENT  
1
Gas Valve  
Natural Gas  
LP (Propane) Gas  
810-0786  
810-0787  
2
3
813-0378 Fitting, Cross, ” NPT, Brass  
813-0154 Plug, Pipe, ” Hex Head  
4
5
813-0340 Adapter, ” NPT x ” Tube, Brass  
813-0016 Nipple, ” x ¾” NPT, BM  
6
813-0004  
Elbow, ” NPT x 90°, BM  
7
8
9
10  
11  
12  
13  
14  
15  
*
813-0433 Nipple, ” NPT x 2 ½”, BM  
813-0304 Bushing, ½” x ¼” Flush, BM  
813-0301 Tee, Male, ” x ¼” NPT x ”, 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  
5
16  
11  
12  
6
1
4
13  
7
15  
3
10  
14  
2
17  
8
20  
9
19  
18  
ITEM  
1
PART #  
806-9067 Valve Assembly, Solenoid (FBRA18 only)  
810-1208 Valve, Water Pressure Regulator (FBRA18 only)  
COMPONENT  
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
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 ” 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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