Frymaster, a member of the Commercial Food Equipment Service Association, recommends
using CFESA Certified Technicians.
819-5686
24-Hour Service Hotline 1-800-551-8633
March 2005
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FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS
TABLE OF CONTENTS
CHAPTER 1: General Information
1.1 Parts Ordering and Service Information ............................................................................1-1
1.2 Safety Information .............................................................................................................1-1
1.3 Equipment Description ......................................................................................................1-2
1.4 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 FBCR18 Series Computer..................................................................................................3-1
Programming the FBCR18 Series Computer.....................................................................3-2
Operating the FBCR18 Series Rethermalizer....................................................................3-2
Using the FBCR18 Chill Feature.......................................................................................3-3
FBCR18 Temperature Display Options.............................................................................3-3
FBCR18 Computer Display Messages ..............................................................................3-3
3.3 FBKR18 Series Computer .................................................................................................3-3
Programming the FBKR18 Series Computer ....................................................................3-4
Operating the FBKR18 Series Rethermalizer....................................................................3-6
FBKR18 Temperature Display Options.............................................................................3-7
FBKR18 Computer Display Messages ..............................................................................3-7
FBKR18 Boil or Simmer Mode Options ...........................................................................3-7
FBKR18 Clock Speed Options..........................................................................................3-7
3.4 Start-Up Procedure.............................................................................................................3-8
3.5 Boiling Out the Cookpot....................................................................................................3-9
3.6 Shutting the Rethermalizer Down......................................................................................3-9
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
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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
Computers ......................................................................................................................... 6-2
Interface Board.................................................................................................................. 6-2
Temperature Probe ............................................................................................................ 6-3
Water Level Sensors.......................................................................................................... 6-3
6.2 Accessing the Rethermalizer for Servicing....................................................................... 6-3
6.3 Cleaning the Gas Valve Vent Tube................................................................................... 6-6
6.4 Checking the Burner Manifold Gas Pressure.................................................................... 6-4
6.5 Measuring Flame Current.................................................................................................. 6-4
6.6 Replacing Components...................................................................................................... 6-4
6.6.1 Replacing the Computer or Computer Wiring Harness .................................................... 6-4
6.6.2 Replacing the Temperature Probe ..................................................................................... 6-4
6.6.3 Replacing the Interface Board........................................................................................... 6-5
6.6.4 Replacing an Ignition Module........................................................................................... 6-5
6.6.5 Replacing an Ignitor Assembly ......................................................................................... 6-6
6.6.6 Replacing the Combustion Air Blower ............................................................................. 6-6
6.6.7 Replacing the Gas Valve ................................................................................................... 6-6
6.6.8 Replacing a Burner Assembly........................................................................................... 6-7
6.6.9 Replacing the Cookpot ...................................................................................................... 6-7
6.7 Troubleshooting and Problem Isolation ............................................................................ 6-8
6.7.1 Ignition Failures ................................................................................................................ 6-9
6.7.2 Improper Burner Functioning............................................................................................ 6-9
6.7.3 Improper Temperature Control ....................................................................................... 6-11
6.7.4 Computer-Related Problems ........................................................................................... 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 .............................................................................. 6-14
6.8.3 Troubleshooting the Temperature Probe......................................................................... 6-16
Probe Resistance Chart.................................................................................................... 6-17
6.9 Simplified Wiring Diagrams ........................................................................................... 6-18
CHAPTER 7: Parts List
7.1 Burner System Components.............................................................................................. 7-1
7.2 Cabinetry and Associated Components............................................................................. 7-2
7.3 Computer, Component Box Assembly, and Associated Parts .......................................... 7-3
7.4 Cookpot and Associated Parts........................................................................................... 7-4
7.5 Gas Supply Components ................................................................................................... 7-5
7.6 Plumbing Components ...................................................................................................... 7-6
ii
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FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS
CHAPTER 1: GENERAL INFORMATION
1.1
Applicability and Validity
This manual is applicable to and valid for all FBCR18 and FBKR18 units sold in English-
speaking countries. Where conflicts exist between instructions and information in this manual
and local or national codes of the country in which the equipment is installed, installation and
operation shall comply with those codes.
This appliance is only for professional use and shall be used by qualified personnel only, as
defined in Section 1.6.
1.2
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.
1-1
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1.3
Safety Information
Before attempting to operate your unit, read the instructions in this manual thoroughly.
Throughout this manual, you will find safety notations enclosed in double-bordered boxes similar to
the one below.
DANGER
DANGER boxes contain information about actions or conditions that may cause or
result in injury to personnel, and which may cause damage to your system and/or
cause your system to malfunction.
CAUTION boxes contain information about actions or conditions that may cause or result in a
malfunction of your system.
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 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.
1.4
Equipment Description
The FBCR18 and FBKR18 Series Gas Rethermalizers are specifically designed to rethermalize
meats, sauces, and other vacuum packaged foods at a safe temperature range that prevents overcook-
ing. They can be configured for either natural or LP (Propane) gas, and their efficient infrared burn-
ers deliver 90,000 BTUs (94.9 MJ – 26.4 kW).
The systems feature programmable computer controls and an easy to clean automatically filled
cookpots. The FBKR18 also has a manual-fill switch. Each unit can rethermalize up to 15 lbs. (7kg)
of food an hour.
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.
1.5
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 1.6.
1-2
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1.6
Definitions
QUALIFIED AND/OR AUTHORIZED OPERATING PERSONNEL
Qualified/authorized operating personnel are those who have carefully read the information in this
manual and have familiarized themselves with the equipment functions, or who have had previous
experience with the operation of the equipment covered in this manual.
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 person-
nel are required to be equipped with a complete set of service and parts manuals, and to stock a pre-
scribed 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.
1.7
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
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FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS
CHAPTER 2: INSTALLATION INSTRUCTIONS
2.1
General Installation Requirements
Qualified, licensed, and/or authorized installation or service personnel, as defined in Section
1.6 of this manual, should perform all installation and service on Frymaster equipment.
Conversion of this appliance from one type of gas to another should only be performed by
qualified, licensed, and/or authorized installation or service personnel as defined in Section 1.6
of this manual.
Failure to use qualified, licensed, and/or authorized installation or service personnel (as
defined in Section 1.6 of this manual) to install, convert to another gas type or otherwise
service this equipment will void the Frymaster warranty and may result in damage to the
equipment or injury to personnel.
Where conflicts exist between instructions and information in this manual and local or
national codes or regulations, installation and operation shall comply with the codes or
regulations in force in the country in which the equipment is installed.
Upon arrival, inspect the rethermalizer carefully for visible or concealed damage. (See Shipping
Damage Claim Procedure in Chapter 1.)
WARNING
Frymaster appliances equipped with legs are for stationary installations. Appliances
fitted with legs must be lifted during movement to avoid damage to the appliance
and bodily injury. For movable installations, optional equipment casters must be
used. Questions? Call 1-800-551-8633.
CLEARANCE AND VENTILATION
DANGER
No structural material on this appliance should be altered or removed to accommo-
date placement of the appliance under a hood. Questions? Call the Frymaster/Dean
Service Hotline at 1-800-551-8633.
DANGER
This appliance must be installed with sufficient ventilation to prevent the occurrence
of unacceptable concentrations of substances harmful to the health of personnel in
the room in which it is installed.
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.
2-1
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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
become 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.
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
DANGER
This appliance is equipped with a three-prong (grounding) plug for your protection
against electrical shock, and must be plugged directly into a properly grounded
three-prong receptacle. Do not cut, remove, or otherwise bypass the grounding
prong on this plug!
DANGER
This appliance requires electrical power for operation. Place the gas control valve in
the OFF position in case of a prolonged power outage. Do not attempt to operate
this appliance during a power outage.
2-2
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All electrically operated appliances must be grounded in accordance with all applicable national and
local codes. A wiring diagram is located on the inside of the door. In the United States and Canada,
the electrical supply must be 120VAC, 60 Hz. In other countries, refer to the rating plate on the
inside of the door for proper voltages.
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
Depending upon the specific configuration ordered, your unit may have been shipped without in-
stalled casters or legs. If casters or legs are installed, you may skip this section and proceed to Sec-
tion 2.3, Pre-Connection Preparations.
If your unit requires the installation of casters/legs, install them in accordance with the in-
structions included in your accessory package.
2.3
Pre-Connection Preparations
DANGER
Do not connect this equipment to the gas supply before completing each step in this
section.
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
connected at all times when the equipment is in use. The restraining cable and installation
instructions are packed with the flexible hose in the accessories box that was shipped with your
unit.
2-3
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2. The rethermalizer must be stabilized by installing restraining chains on units equipped with
casters or anchor straps on units equipped with legs. Follow the instructions shipped with the
casters/legs to properly install the chains or straps.
3. Level rethermalizers equipped with legs by screwing out the legs approximately 1 inch then
adjusting them so that the rethermalizer is level.
4. For rethermalizers equipped with casters, there are no built-in leveling devices. The floor where
the rethermalizer is to be installed must be level.
DANGER
Do not attach an apron drain board to this unit. The appliance may become
unstable, tip over, and cause injury. The appliance area must be free and clear of
combustible material at all times.
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.
However, on FBCR18 units, connecting to hot water will lower the efficiency of the chill fea-
ture.
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 computer’s ON/OFF button. °-Lo or c y c l should appear in the display.
6. Turn the computer 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
2-4
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2.4
Connecting to the Gas Supply
DANGER
Before connecting new pipe to this appliance, the pipe must be blown out thor-
oughly to remove all foreign material. Foreign material in the burner and gas con-
trols will cause improper and dangerous operation.
DANGER
When pressure-testing incoming gas supply lines, disconnect the appliance from the
gas line if the test pressure will be ½ PSIG (3.45 kPa, 13.84 inches W.C.) or greater to
avoid damage to the appliance’s gas tubes and gas valve(s).
DANGER
All connections must be sealed with a joint compound suitable for the gas being
used and all connections must be tested with a solution of soapy water before light-
ing any pilots.
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 appliance at the main shut-off
valve and immediately contact the local gas company or an authorized service
agency for service.
DANGER
“Dry-firing” your unit will cause damage to the cookpot. Always ensure that water
is in the cookpot before firing the unit.
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.
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.
2-5
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2. Open the gas supply to the fryer and check all piping, fittings, and gas connections for leaks. A
soap and water solution should be used for this purpose.
3. Close the drain valve and fill the cookpot with water and boil-out solution to the overflow. Light
the burners and perform the boil-out procedures that are described in the “Start-Up Procedure”
and “Boiling Out the Cookpot” sections in Chapter 3 of this manual.
4. 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
This appliance was configured at the factory for a specific type of gas. Converting
from one type of gas to another requires the installation of specific gas-conversion
components.
Switching to a different type of gas without installing the proper conversion kit may
result in fire or explosion! NEVER ATTACH THIS APPLIANCE TO A GAS SUPPLY
FOR WHICH IT IS NOT CONFIGURED.
Conversion of this appliance from one type of gas to another should only be
performed by qualified, licensed, and authorized installation or service personnel, as
defined in Section 1.6 of this manual.
2-6
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FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS
CHAPTER 3: OPERATING INSTRUCTIONS
3.1
Introduction
WARNING
The on-site supervisor is responsible for ensuring that operators are made aware of
the inherent hazards of operating a gas-fired heated water system, particularly the
aspects of draining and cleaning procedures.
Mechanically, the FBCR18 and FBKR18 rethermalizers are virtually identical. The FBKR18 units
have a manual fill switch in addition to the AutoFill feature.
The primary difference between the two rethermalizers is the controller. Both units use modified
Computer Magic III (CM III) computers. Although the computers are very similar in appearance
(and to standard CM III computers), they are not interchangeable.
3.2
FBCR18 Series Computer
This computer has 12 programmable product buttons and a “chill” switch. The chill switch shuts
off the burners, but does not turn off the computer. This allows unused product to be quickly
cooled before being returned to a refrigerator or freezer.
The product buttons are multi-functional. In the programming mode, each button can be
programmed for a distinct rethermalizing time. In the rethermalizing mode, pressing a button
initiates a specific timed countdown.
1
1
2
3
4
5
6
5
FBCR18 Series Computer
1
2
3
LED Displays
Chill Switch
Temperature Check/Program Lock
4
5
6
Power Switch
Product Buttons
Program Mode Switch
3-1
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PROGRAMMING THE FBCR18 SERIES COMPUTER
1. Turn the computer on by pressing the Power
switch.
2. Press the Program Mode
switch. CodE appears in the left display. Press, in sequence,
product buttons 1, 6, 5, and 10. (Press switch again to exit the programming mode.)
NOTE 1: The programming mode is not available while the computer is rethermalizing; the
display will flash BUSY.
NOTE 2: To toggle between Fahrenheit and Celsius temperature display, press the Program
Mode
switch, then enter the code 1 6 5 8 by pressing the corresponding product buttons.
Next, press the Temperature Check/Program Lock switch to lock in the new display option.
3. SP- is displayed in the left window and the setpoint in the right. Use the product buttons to
change the temperature up to 205°F (96°C). For example, pressing 1, 9, and 5 programs the
setpoint for 195°. When the correct setpoint is displayed, press the Program Mode switch.
4. SELP (Select Product) appears in the display and the LEDs in the product buttons blink. Press
any of the product buttons to select it for programming.
5. PULL appears in the display. Press the product buttons to enter the desired heating time in
minutes and seconds. Press the Program Mode switch to lock it in.
6. SELP again appears in the display. To program the heating time for another product, press the
product button to be associated with it and repeat Step 5.
7. Press the Program Lock switch to exit the programming mode.
OPERATING THE FBCR18 SERIES RETHERMALIZER
1. Press the Power
switch. The AutoFill feature will activate if the water level is below the
upper water level sensor.
2. CYCL appears in the display and the unit enters a burner on/off cycle until the water in the
cookpot reaches 180°F (82°C). At that time, the display changes to -Lo- and the burners fire
continuously. When the water in the cookpot is within 3°F of setpoint, the display changes to
four dashes (- - - -), indicating that the unit is ready for use. NOTE: To view the water
temperature, press the Temperature Check button once. Press the button twice to display the
setpoint.
3. After the four dashes appear in the display, place the product basket in the cookpot and press
the corresponding product button. The display counts down the heating time. The display
changes to PULL. The small LED in the product button blinks and an alarm sounds to alert you
to remove the product. Press the button to silence the alarm.
USING THE FBCR18 CHILL FEATURE
3-2
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If you rethermalize more food than you use, use the chill feature to quickly reduce the temperature
of the food before refrigerating or freezing.
1. Press the Chill Mode
switch to de-energize the heating elements.
2. Open the drain valve and drain most of the hot water. The AutoFill will refill the cookpot with
cold water. If desired, add ice to the cookpot to accelerate the cooling process.
3. Remove the product bags when cooled and return them to the refrigerator or freezer.
FBCR18 TEMPERATURE DISPLAY OPTIONS
NOTE: To enter the prgramming mode, press the Program Mode switch. When the display
reads CodE:
ꢀ
Enter 1, 6, 5, 1 to toggle constant temperature display on and off. NOTE: When in
constant temperature display mode, the countdown time will not be displayed.
ꢀ
Enter 1, 6, 5, 8 to toggle between Fahrenheit and Celsius temperature display.
FBCR18 COMPUTER DISPLAY MESSAGES
ꢀ
ꢀ
ꢀ
ꢀ
ꢀ
SELP – Prompts you to select a product button for programming.
CodE – Prompts you to enter a sequence of numbers to change functions.
CYCL – Indicates the rethermalizer is in the burner on/off cycle mode.
-HI- – Indicates the water temperature is more than 3°F above setpoint.
-Lo- – Indicates that the water temperature is more than 3°F below setpoint.
ꢀ
ꢀ
ꢀ
- - - - (four dashes) – Indicates the water temperature is within the proper rethermalizing
range (i.e., within ±3°F of setpoint).
HELP – Indicates a heating problem. Call your local Frymaster Factory Authorized Service
Center or the 24-Hour Hotline (1-800-551-8633).
Prob - Indicates a problem in the temperature control circuits. Call your local Frymaster
Factory Authorized Service Center or the 24-Hour Hotline (1-800-551-8633).
3.3
FBKR18 Series Computer
This computer has 10 programmable product buttons, a Simmer Mode switch, and a Boil Mode
switch. The computer also has two Power switches; press either switch to turn the unit on and off.
The product buttons are multi-functional. In the programming mode, each button can be
programmed for a distinct rethermalizing time. In the rethermalizing mode, pressing a button
initiates a timed countdown of a specific product.
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Pressing the Boil Mode (L) switch overrides the programmed setpoint and the cookpot temperature
rises to boiling at 212°F (100°C). When the unit is in boil mode, boiL appears in both LED
displays. The unit remains in boil mode until the Simmer Mode switch is pressed or the unit is
turned off.
Pressing the Simmer Mode (R) switch causes the cookpot temperature to be maintained at the
programmed setpoint. If the cookpot temperature is above the setpoint, °-HI is displayed in both
LED widows. If the cookpot temperature is below the setpoint, °-Lo is displayed. Four dashes
(- - - -) are displayed if the temperature is within 11°F (6°C) of setpoint.
1
1
2
3
2
6
7
5
4
8
FBKR18 Series Computer
1
2
3
4
LED Displays
Power Switches
Temperature Check/Program Lock
Program Mode Switch
5
6
7
8
Boil Mode Switch
Product Buttons 1 through 5
Product Buttons 6 through 10
Simmer Mode Switch
PROGRAMMING THE FBKR18 SERIES COMPUTER
CAUTION
It is recommended that the simmer setpoint and the heat/stir times for all 10
products be programmed before the unit is first used in a rethermalizing cycle.
The simmer setpoint and product rethermalizing times are programmed at the factory. These are
test settings not default settings. You must program the unit for your own particular products.
Program the setpoint and all product rethermalizing times as follows:
1. Turn the computer on by pressing the Power
switch.
2. Enter the programming mode by pressing the Program Mode
switch. CodE appears in the
left display. Press the switch again to exit the programming mode.
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NOTE 1: Programming mode is not available while the computer is rethermalizing; the display
will flash BUSY.
NOTE 2: To toggle between Fahrenheit and Celsius temperature display, press the Program
Mode
switch, then enter the code 1 6 5 8 by pressing the corresponding product buttons.
Next, press the Temperature Check/Program Lock switch to lock in the new display option.
3. Enter the number 1 6 5 0 by pressing the corresponding product buttons. Unless this code is
entered, programming will not be accepted. This is to prevent unauthorized changes to your
current instructions.
4. SP- r (Setpoint) appears in the left LED display. Any previously programmed temperature
setpoint appears in the right display. To change the setpoint, enter the desired setpoint
temperature using the corresponding product buttons. The setpoint can be programmed for any
value up to 212°F (100°C). Press the Program Mode
the old setpoint, if it was not changed).
switch to lock in the new setpoint (or
5. SELP (Select Product) appears in the left display. Press the product button to be programmed
(or press to return to the normal operating mode).
6. COOC (Rethermalizing Time) appears in the left display. Any previously programmed
rethermalizing time will appear in the right display. Press
to accept the current
rethermalizing time or enter a new time using the product buttons. The rethermalizing time can
be programmed up to 59:59. Press to lock in the new time.
NOTE: The computer can be programmed for either “standard” or “slow” clock. The standard
clock displays minutes and seconds, the slow clock displays hours and minutes. To toggle back
and forth between times press the Program Mode
the product buttons. Press the Temperature Check/Program Lock
switch, then enter the code 1 6 5 3 using
switch to lock in the clock
speed. To determine whether the clock speed is set to standard or slow, initiate a rethermalizing
cycle by pressing a product button. If the computer is set to the standard clock, the time in the
LED display will immediately begin to count down. If it does not, the computer is set to the
slow clock.
7. SH1 (Stir Time 1) appears in the left display. Enter the number of seconds to heat before the
stir alarm sounds using the product buttons; for no stir alarm, enter “0”. The number entered
will appear in the right display. For example, entering “30” means the product needs to be
stirred after it has been rethermalizing for thirty seconds.
The stir time can be programmed up to 59:59, but must not exceed the product rethermalizing
time. Press to lock in the programmed time.
SH2 appears. Program the time of the second stir alarm as above, being sure that the time
entered is greater than that for stir alarm 1 or else is “0”.
SH3 appears. Program the time of the third stir alarm in the same manner as for Stir Times 1
and 2, being sure that the time entered is greater than that for stir alarm 2 or else is “0”.
CAUTION
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Remember: Stir time 2 must be greater than stir time 1 (or else be “0”). Stir time 3
must be greater than stir time 2 (or else be “0”). None of the stir times should be
greater than the rethermalizing time entered in Step 6. If a stir time exceeds the
rethermalizing time, the stir alarm will not sound.
8. SELP (Select Product) again appears in the left display. Return to Step 5 and follow all
instructions to program more products.
9. Lock in the programming by pressing the Temperature Check/Program Lock Switch
.
OPERATING THE FBKR18 SERIES RETHERMALIZER
Turn the computer on by pressing the Power
switch. NOTE: A decimal between digits 1 and 2
in either LED Display indicates that the element is energized.
1. One of the following is displayed:
a. °-Lo, indicates the cookpot temperature is 11ºF (6ºC) lower than the setpoint.
b. °-HI, indicates the cookpot temperature is 11ºF (6ºC) higher than the setpoint.
c. - - - - (four dashes), indicates the cookpot temperature is in the rethermalizing range.
d. HELP, indicates a heating problem.
e. Prob, indicates a problem with the computer temperature probe circuit.
2. Press a product button to initiate a rethermalizing cycle.
a. The programmed rethermalizing time appears and the timer countdown will begin.
b. Stir alarms, if programmed, will sound, the display will read Stir, and the LED in the
product button will blink. Press the indicated product button to cancel the alarms.
CAUTION
Pressing the product button twice while the alarm is active will cancel the
rethermalizing cycle as well as the alarm.
c. An alarm sounds at the end of the cycle. COOC is displayed, and the associated product
button flashes. To cancel the alarm, press the flashing button.
3. Press the Temperature Check switch once to check the cookpot temperature. Press the switch
twice to check the setpoint.
4. During idle periods, four dashes (- - - -) should appear in both displays, indicating that the
cookpot is at setpoint.
FBKR18 TEMPERATURE DISPLAY OPTIONS
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To change the temperature display, press the Program Mode
display.
switch; CodE appears in the
ꢀ
To toggle constant temperature display on and off, enter 1, 6, 5, 1, . NOTE: When in
constant temperature display mode, the countdown time will not be displayed.
ꢀ
To toggle between Fahrenheit and Celsius temperature display, enter 1, 6, 5, 8,
.
FBKR18 COMPUTER DISPLAY MESSAGES
ꢀ
ꢀ
ꢀ
ꢀ
SELP – Prompts you to select a product button for programming.
CodE – Prompts you to enter a sequence of numbers to change functions.
°-HI – Indicates that the water temperature is more than 3°F above setpoint.
°-Lo – Indicates that the water temperature is more than 3°F below setpoint.
ꢀ
ꢀ
ꢀ
- - - - (four dashes) – Indicates that the water temperature is within the proper
rethermalizing range (i.e., within ±3°F of setpoint).
HELP – Indicates a heating problem. Call your local Frymaster Factory Authorized Service
Center or the 24-Hour Hotline (1-800-551-8633).
Prob – Indicates a problem in the temperature control circuits. Call your local Factory
Authorized Service Center or the 24-Hour Hotline (1-800-551-8633).
FBKR18 BOIL OR SIMMER MODE OPTIONS
Pressing the Boil Mode (L) switch overrides the programmed setpoint and the cookpot temperature
rises to boiling at 212°F (100°C). When the unit is in boil mode, boiL appears in both LED
displays. The unit remains in boil mode until the Simmer Mode switch is pressed or the unit is
turned off.
Pressing the Simmer Mode (R) switch causes the cookpot temperature to be maintained at the
programmed setpoint. If the cookpot temperature is above the setpoint, °-HI is displayed in both
LED widows. If the cookpot temperature is below the setpoint, °-Lo is displayed. Four dashes
(- - - -) are displayed if the temperature is within 11°F (6°C) of setpoint.
FBKR18 CLOCK SPEED OPTIONS
The computer can be programmed for either “standard” or “slow” rethermalizing times. The
standard clock displays minutes and seconds, the slow clock displays hours and minutes. To
toggle back and forth between times press the Program Mode
switch, then enter 1, 6, 5, 3,
. To determine whether the clock speed is set to standard or slow, initiate a rethermalizing
cycle by pressing a product button. If the computer is set to the standard clock, the time in the
LED display will immediately begin to count down. If it does not, the computer is set to the
slow clock.
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3.4
Start-Up Procedure (Applies to both the FBCR18 and FBKR18)
WARNING
Never operate this appliance with an empty cookpot. The cookpot must be filled
with water before lighting the burners.
CAUTION
If this is the first time the unit is being used after installation, refer to Section 3.5,
Boiling-Out the Cookpot.
Before turning the rethermalizer on, ensure that:
●
●
●
●
●
the unit is connected to the water supply
that the water supply is turned on
that the unit is plugged into a 120VAC outlet
that the electrical power supply to the rethermalizer is turned on
that the gas supply to the rethermalizer is turned on.
1. Turn the gas valve to the ON position (see illustration below).
2. Press the computer Power
switch. (On FBKR18 units, press either power switch.)
The AutoFill will, if necessary, add water until it reaches the upper water level sensor. The
AutoFill solenoid valve will cut off the water flow.
On FBKR18 Series units, a manual fill momentary switch (located on the component box cover
inside the door) may be pressed to override the solenoid valve and add water to the unit. Water is
added as long as the switch is pressed.
When the water level is above the lower water level sensor, the burners light for several seconds
then go out. A few seconds later they will light again. This cycle repeats until the water reaches
180°F (82°C). The burners then remain lit until the setpoint is reached. During the cycling,
FBCR18 Series units display CYCL. At 180°F (82°C), the display changes to °-Lo. FBKR18
Series units will display °-Lo. For either series, when the unit reaches setpoint, the display changes
to four dashes (- - - -), indicating the unit is ready for use.
Observe the burners through the burner viewing ports after 90 seconds of ignition. Look for a
bright orange-red glow. A blue flame or dark spots on a burner face indicate the air/gas mixture
requires adjustment. Refer to Chapter 4, Section 4.4, Clean Combustion Air Blower for adjustment
procedures.
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3.5
Boiling-Out the Cookpot
DANGER
Never leave the appliance unattended during the boil-out process. If the boil-out so-
lution boils over, turn the appliance off immediately and let the solution cool for a
few minutes before resuming the process. To lessen the chance of boil over, turn
the appliance’s gas valve knob to the PILOT position occasionally.
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 boil-out
solution or detergent.
2. Place the unit into operation in accordance with Section 3.4.
3. On FBCR18 Series units, program the setpoint for 195°F (91°C). Program one of the product
buttons for 59 minutes and 59 seconds. Initiate the heating cycle by pressing the button.
On FBKR18 Series units, press the Boil (L) switch and allow the boil-out solution to boil for
one hour.
4. After the solution heats 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.
6. On FBCR18 Series units, reprogram the setpoint to the appropriate temperature, and reprogram
the product button for the appropriate time.
3.6
Shutting the Rethermalizer Down
1. Turn the unit off by pressing the Power
switch (on FBKR18 units, press either switch).
2. Drain and clean the cookpot, put the cookpot cover in place, and turn the gas valve to the OFF
position. (See illustration below.)
CAUTION
The electronic circuitry in your computer can be affected adversely by current
fluctuations and electrical storms. Should it fail to function or program properly for
no apparent reason, the computer should be reset by unplugging the computer and
plugging it back in. This could prevent a service call.
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FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS
CHAPTER 4: PREVENTIVE MAINTENANCE
4.1
Daily Checks and Services
Inspect Rethermalizer and Accessories for Damage
Look for loose or frayed wires and cords, leaks, foreign material in cookpot or inside cabinet, and
any other indications that the rethermalizer and accessories are not ready and safe for operation.
Clean Cabinet Inside and Out
Clean inside the cabinet with a dry, clean cloth. 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 this appliance when it is in use or filled with water heated to
cooking/rethermalizing temperature.
WARNING
Use a commercial-grade cleaner formulated to effectively clean and sanitize food-contact
surfaces. Read the directions for use and precautionary statements before use. Particular
attention must be paid to the concentration of cleaner and the length of time the cleaner
remains on the food-contact surfaces.
Clean Water-Level Sensors, Temperature Probe, and Cookpot
Press the computer power switch to the OFF position.
Remove the cap nut at the top of the shield (located on the left front of the cookpot) 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.
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.
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4.2
Quarterly Checks and Services
Check Computer Magic III Set Point Accuracy
1. Fill the cookpot with water. Press the computer power switch, and then press any of the product
buttons. Insert a good-grade thermometer or pyrometer probe into the cookpot, with the end
touching the temperature probe at the lower right front of the cookpot.
2. When the computer display shows a series of four dashes (- - - -), press the
switch once to
switch
display the temperature of the water as sensed by the temperature probe. Press the
twice to display the set 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
adjustment.
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
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open or close the air intake opening until a bright orange-red glow is obtained. Carefully hold
the plate in position and retighten the nut(s).
Clean Gas Valve Vent Tube
1. Set the rethermalizer power switch and the gas valve to the OFF position.
2. Carefully unscrew the vent tube from the gas valve. NOTE: The vent tube may be straightened
for ease in removal.
Vent Tube
3. Pass a piece of ordinary binding wire (.052 inch diameter) through the tube to remove any
obstruction.
4. 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
DANGER
This task should be performed by qualified service personnel only. The cookpot
must be filled with water during this procedure.
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
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3. Place the gas valve in the ON position. Place the computer power switch in the ON position.
When the burner lights and continues to burn, compare the indicated pressure to the table
below.
Burner Manifold Gas
Pressures
Gas
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 rethermalizer power switch and the gas valve in the OFF position. Remove the fitting
from the pressure tap hole and reinstall the pressure tap plug.
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FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS
CHAPTER 5: OPERATOR TROUBLESHOOTING
5.1
Introduction
DANGER
Water heated to cooking/rethermalizing temperature will cause severe burns. Never
attempt to move this appliance when filled with heated water or to transfer heated
water from one container to another.
DANGER
This equipment should be unplugged when servicing, except when electrical circuit
tests are required. Use extreme care when performing such tests.
This appliance may have more than one electrical power supply connection point.
Disconnect all power cords before servicing.
Inspection, testing, and repair of electrical components should be performed by an
authorized service agent only.
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.
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5.2
Troubleshooting Guides
COOKPOT DID NOT
FILL WHEN UNIT WAS
TURNED ON. WATER
SUPPLY TO UNIT
VERIFIED TO BE ON.
Computer is not functioning.
Probable causes are failed 12V
transformer, failed interface
board, or failed computer.
Did anything
appear in CM III display
when unit was
No
turned on?
Yes
Open control panel
by removing screws
in upper corners.
Is WATER
LED on interface board
illuminated?
No
Yes
Use bottle brush to
clean water level
sensors.
Probable causes are a failed
interface board or a failed
high-level water sensor.
Did LED
illuminate?
No
Yes
Probable causes are a failed
water solenoid or a failed
interface board.
Did unit
begin to fill?
Problem resolved.
Yes
No
Call FASC.
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WATER NOT
HEATING. AUTOFILL
WORKED PROPERLY.
Press the
Temperature
Check button twice
to display setpoint.
Is the
displayed setpoint
correct?
Enter correct setpoint in
accordance with
instructions in Chapter 3.
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 the
temperature probe and wait two
minutes. Press the Temperature
Check button once to display the
cookpot temperature.
Did water
reach setpoint
temperature?
No
Yes
Is the temperature
displayed reasonably close to
the thermometer
There is a problem in
the temperature probe
circuit. Call FASC.
Problem
resolved.
No
reading?
Yes
Temperature control
features are working properly.
If water still fails to reach
setpoint, call FASC.
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BURNERS DO
NOT LIGHT.
Verify that correct setpoint has
been programmed, that main gas
supply valve is open, and that
equipment gas valve is set to ON.
Press ON/OFF button.
Did burners
light?
Yes
Problem resolved.
No
Use bottle brush to clean low
water sensor. If burners still do
not light, remove the cover over
the water sensors and thoroughly
clean them with a scouring pad.
Did burners
light?
Yes
Problem resolved.
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.
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CM III WILL NOT GO INTO
PROGRAMMING MODE OR
DOES NOT ACCEPT
CHANGES TO PROGRAM.
Press Power Switch OFF,
disconnect unit from electrical
power, open control panel by
removing screws in upper corners,
and unplug wiring harness from
interface board. Wait two minutes.
Reconnect computer wiring
harness, close control panel,
reconnect unit to electrical power,
and press Power Switch ON.
Does
computer operate
properly?
Problem
resolved.
Yes
No
Press Power Switch OFF,
disconnect unit from electrical
power, open control panel,
remove computer and replace
with another known to be working.
Close control panel, reconnect
unit to electrical power, and press
Power Switch ON.
Problem is beyond
scope of operator
troubleshooting.
Does
computer operate
properly?
Probable cause is
a defective or failed
computer.
No
Yes
Call FASC.
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5.3
Replacing the Computer or Computer Wiring Harness
1. Disconnect the rethermalizer from the electrical supply.
2. Remove the two screws in the upper corners of the control panel and swing the panel open from
the top, allowing it to rest on its hinge tabs.
3. Disconnect the wiring harness from the back of the computer. If replacing the harness, 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 computer. 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 computer, remove the nuts securing the computer to the control panel and install
the replacement computer on the control panel. Reverse steps 1-4 to complete the procedure.
Wiring Harness
Connection
Ground Wire
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FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS
CHAPTER 6: SERVICE PROCEDURES
6.1
Functional Description
These rethermalizers contain a welded stainless steel cookpot that is directly heated by a high
efficiency burner system requiring approximately 43% less energy than conventional burner systems
to heat the same volume of water.
Two self-contained combustion chambers (referred to as “burners”) are located beneath the cookpot.
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 ignition module performs four important functions: it provides fuse protection for the 24-volt
circuit, provides an ignition spark, supplies voltage to the gas valve, and proofs the burner flame.
The module contains a 4-second time delay circuit and a coil that activates the gas valve. The
ignitor assembly consists of a spark plug, an enrichment tube, and a flame sensor.
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 or computer and to one side of the heat relay coil on the
interface board. If resistance in the temperature probe indicates the temperature in the cookpot is
below 180ºF (82ºC), the current flows through a circuit containing a timer switch that alternately
closes for 6 seconds and opens for 24 seconds. If the temperature is 180ºF (82ºC) 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 relay coil, which then closes an electronic switch in the 24 VAC circuit to
provide current to the ignition 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
extinguished), current to the ignition module is cut, preventing the main valve from opening, and the
ignition 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.
6-1
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Inside the Ignition Module
Out to
Gas Valve
To Alarm
25 V +
Coil
TD
HV
25 V GND
Ignition Wire
Flame Sensor
COMPUTERS
These rethermalizers are equipped with Computer Magic III computers that have been modified for
this specialized application. Although similar in appearance to standard Computer Magic III
computers, the standard CM III computers will not operate the unit correctly. Only part number
806-8063 may be used in FBCR18 units and only part number 806-9352 may be used in FBKR18
units.
INTERFACE BOARD
An interface board is located in the component box directly behind the control panel. The interface
board provides a link between the computer and the rethermalizer’s individual components without
requiring excessive wiring, and allows the computer to execute commands from one central point.
The part number for the interface board used in this equipment is 806-9295. A simplified
illustration of the board is provided below.
J2
J4
J4
HI
J1
K1
OPT
B/L-R
K2
OPT
B/L-L
K5
BLOWER
LATCH
K4
HEAT
WATER
HEAT
K3
LATCH
K6
WATER
ORANGE
RESISTOR
GND +15V
J3
LO
The board contains a heat relay (K4) that switches 24VAC to the ignition and gas valve circuits
when the computer heat logic circuit calls for heat. Relay K5 switches 120VAC to the blower motor
when K4 closes. The water relay (K6) has two functions. First, it breaks the 24VAC circuit when
the water level in the cookpot is below the lower water level sensor. This prevents the burners from
firing when the unit is empty. The second function is to supply power to the normally open water
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solenoid valve when the water level reaches the upper water level sensor and to de-energize the
solenoid when the water level drops below the upper water level sensor.
The board has four LEDs to assist in troubleshooting. Three of the LEDs (LATCH, WATER, and
HEAT) are located just to the right of the heat relay (K4). The fourth LED is not labeled. It is
located in the lower left portion of the board, just above a large orange resistor. When the latch,
water, and heat LEDs are illuminated, they indicate that the associated relay is closed. The
unlabeled 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
thermostat in which the resistance varies directly with the temperature. That is, as the temperature
rises, so does resistance, at a rate of approximately 2 ohms for every 1° of rise or fall. Circuitry in
the computer 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
number buttons on the face of the computer.
WATER LEVEL SENSORS
Two water level sensors are arranged one above the other on the left front of the cookpot. 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 blower relay (K5) pulls in, supplying
power to the blower and to the gas valve via the ignition modules. Grounding the upper water level
sensor causes another transistor on the interface board to bias and pull in the water relay (K6) which
closes the water solenoid valve, cutting off water flow into the cookpot.
6.2
Accessing the Rethermalizer for Servicing
DANGER
Water heated to cooking/rethermalizing temperature will cause severe burns. Never
attempt to move this appliance when filled with heated water or to transfer heated
water from one container to another.
DANGER
This equipment should be unplugged when servicing, except when electrical circuit
tests are required. Use extreme care when performing such tests.
This appliance may have more than one electrical power supply connection point.
Disconnect all power cords before servicing.
Inspection, testing, and repair of electrical components should be performed by an
authorized service agent only.
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.
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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
sensing wire on the ignitor. This is accomplished as follows:
1. Turn the unit OFF (press the
button).
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.
Flame Sensor
Ignitor Wire
Wire
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 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.
6.6
Replacing Components
6.6.1 Replacing the Computer or Computer Wiring Harness
Refer to Chapter 5, Section 5.3 for this procedure.
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6.6.2 Replacing the Temperature Probe
1. Unplug the rethermalizer.
2. Drain the cookpot.
3. Remove the screws from the upper corners of the control panel and swing the panel open from
the top, allowing it to rest on its hinge tabs.
4. Remove the cover from the component box by removing the three screws along its bottom edge.
5. Cut the temperature probe wires an inch or so from the 12-pin connector. Leave the cut off wires
in the connector.
6. Remove the temperature probe and install replacement, resealing with Loctite® PST56765 pipe
thread sealant or equivalent. Be careful not to damage the leads when installing the new probe.
7. Thread the leads through opening in the bottom of the component box and through the insulating
sleeve.
8. 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
part.
9. Reattach the 12-pin connector to the interface board, replace the component box cover, and close
and secure the control panel.
6.6.3 Replacing the Interface Board
1. Unplug the rethermalizer.
2. Remove the screws from the upper corners of the control panel and swing the panel open from
the top, allowing it to rest on its hinge tabs.
3. Detach the grounding wire from the computer, 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.
4. Disconnect the 12-pin connector from the interface board.
5. Mark the yellow water level sensor wires and disconnect them from terminals J3 and J5.
6. Remove the nuts in each corner of the interface board and carefully pull the board off the
mounting studs, being careful not to dislodge the spacers on the studs.
7. Position the replacement board on the studs and replace the four nuts.
8. Reconnect the water level sensor wires and the 12-pin connector to the interface board.
9. Remount the control panel to the control panel frame and reattach the grounding wire.
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10. Reattach the 15-pin connector to the interface board.
11. Close and secure the control panel.
6.6.4 Replacing an Ignition Module
1. Unplug the rethermalizer.
2. Remove the screws from the upper corners of the control panel and swing the panel open from
the top, allowing it to rest on its hinge tabs.
3. Remove the component box cover by removing the three screws along its bottom edge.
4. Remove the wires from the ignition module one at a time and mark them to facilitate
reconnection.
5. Remove the four screws securing the ignition module in place and remove the module from the
unit.
6. Remove the four spacers from the back of the old module and insert them into the holes on the
new module, tapered end in.
7. Install the new module in the component box and reconnect the wires removed in step 4.
8. Replace component box cover, and close and secure control pane.
6.6.5 Replacing an Ignitor Assembly
1. Unplug the rethermalizer.
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, making sure that the ignitor (spark plug) is to the
outside.
5. Reconnect the wires 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 and unplug the unit.
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2. Disconnect the unit from the gas supply line and remove any fitting that may be attached to the
gas manifold at the rear of the unit.
3. Disconnect the flexible gas lines at each burner orifice.
4. Disconnect the gas enrichment tubes at the gas valve tee fitting.
5. Disconnect the wires from the gas valve terminal, marking each wire to facilitate reconnection.
6. Remove the two nuts securing the gas manifold bracket to the base frame.
7. Pull the gas manifold assembly out the front of the unit.
8. 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 and the water regulator if this option is selected.)
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.
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.
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7. Reverse steps 1-6 to install replacement burner assembly, being careful to get the insulation strip
running along the top of the blower support bracket back in place.
6.6.9 Replacing the Cookpot
1. Remove the cookpot insert.
2. Remove the top cap by removing the two screws on the front and the screw on each end.
3. Remove the flue cap and lid assembly by removing the two screws on each side and the two
outermost screws on the back. 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
knowledge of the broad problem categories associated with this equipment, and the probable causes
of each. With this knowledge, the technician should be able to isolate and correct any problem
encountered.
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Problems that are likely to be encountered can be grouped into five broad categories:
1. Ignition failures
2. Improper burner functioning
3. Improper temperature control
4. Computer-related problems
5. Autofill System problems.
The probable causes of each category are discussed in the following sections. A series of
Troubleshooting Guides (decision trees) is also included at the end of the chapter to assist in
identifying some of the more common problems.
6.7.1 Ignition Failures
Ignition failure occurs when the ignition module fails to sense a flame within a 4-second time delay
period and locks out. When this happens, the module sends 24 VAC through the interface board
alarm circuit to the computer. The computer then displays h e l p .
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
ignition 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
ignition 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
6-9
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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
replacing 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 computer 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
fluctuating 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.
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If popping is consistent during all hours of operation, the most likely cause is an insufficient air
supply. Check for “negative pressure” conditions in the kitchen area. If air is flowing into the
kitchen area, this indicates that more air is being exhausted than is being replenished, and the
burners may be starved for air.
If the rethermalizer’s gas and air supplies are okay, the problem is most likely with one of the
electrical components. Examine the ignition module and computer for signs of melting/distortion
and/or discoloration due to excessive heat build-up in the equipment. (This condition usually
indicates improper 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 recur.
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
pressure, but may also be the result of variations in the kitchen atmosphere. Verify incoming gas
pressure 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 during 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
procedures 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
defective.
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6.7.3 Improper Temperature Control
Temperature control is a function of several interrelated components, each of which must operate
correctly. The principle component is the temperature probe. Other components include the
interface board, the water level sensors, the computer, and the ignition module. Whatever the cause,
the symptom is failure of the unit to attain or maintain setpoint temperature.
The unit will not call for heat unless the computer senses that the unit is full of water. 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, purified, or highly
filtered water, the water will not ground the sensor. If this is the cause, adding approximately ⅛-cup
of baking soda to the water will 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.
6.7.4 Computer-Related Problems
The computer used in FBKR18 Series rethermalizers is a specially modified Computer Magic III
computer, part number 806-9396. Standard CM III computers will not operate this equipment
correctly. The first thing to check if problems with the computer are experienced should be the part
number.
Most problems concerning the computer have to do with programming it. There are three common
complaints. The complaints, their causes, and corrective actions are:
1. Fryer constantly displays HI.
Cause: Setpoint incorrect or missing.
Corrective Action: Press
setpoint.
16 5 0 , enter the correct setpoint, then press
to lock in the
2. Temperature is displayed in Celsius.
Cause: Computer is programmed to display in Celsius.
Corrective Action: Press
16 5 8 .
3. Temperature is constantly displayed.
Cause: Computer is programmed for constant temperature display.
Corrective Action: Press
i6 5 L.
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.
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6.8.1 Troubleshooting the Gas Valve
MAIN GAS SUPPLY
VALVE VERIFIED TO BE
OPEN AND EQUIPMENT
GAS VALVE IN ON
POSITION.
Is 24VAC
Problem is with
the 24VAC circuit. Refer to
Troubleshooting the
24VAC Circuit.
present on the main
coil (PV terminal) of
the gas valve?
No
Yes
What gas is the unit
configured for?
LP
(Propane)
Natural
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
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
Clear obstruction.
Yes
Problem is not
with gas valve.
No
No
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6.8.2 Troubleshooting the 24 VAC Circuit
WATER LEVEL IN
COOKPOT IS ABOVE
LOWER WATER
LEVEL SENSOR AND
COMPUTER IS
ACTIVATED.
Is 24VAC
present on J2
Pin 7?
Probable cause is a
failed transformer.
No
No
Yes
Probable cause is failed
computer or failed 15-pin
wiring harness.
Is LATCH
LED illuminated?
Yes
Is 12VDC
present on J4
pin 5?
Is combustion
air blower runing?
Probable cause is a
failed computer.
No
No
Yes
Yes
Is 24VAC
present on J2
Pin 4?
Is HEAT LED
illuminated?
Probable cause is a
failed interface board.
Is cookpot filling?
Yes
Yes
No
Yes
No
Probable cause
is a failed interface board
or failed temperature
probe.
Is 24VAC
present on gas
valve?
No
24VAC circuit
is OK.
Yes
Probable causes are blown
ignition module fuse, failed
ignition module, or failed
centrifugal switch in blower, in
that order.
Probable causes are dirty
low water sensor or failed
interface board, in that
order.
No
Is WATER LED
illuminated?
No
No
Yes
Probable causes are
grounded high water level
sensor or failed interface
board.
Is 24VAC
present on J2
pin 2?
Yes
Probable causes are
failed solenoid valve or
broken or loose wire.
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THE 24VAC CIRCUIT
24V LEG OF
DUAL VOLTAGE
TRANSFORMER
J2 PIN 7
LED
K3
K6
K4
WATER
HEAT
J2 PIN 2
J2 PIN 4
BLOWER
CENTRIFUGAL
SWITCH
WATER
SOLENOID
VALVE
LEFT
IGNITION
MODULE
RIGHT
IGNITION
MODULE
GAS
VALVE
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6.8.3 Troubleshooting the Temperature Probe
WHILE IT IS STILL IN
THE COOKPOT,
INSPECT THE PROBE
BODY FOR DAMAGE.
REPLACE IF BENT,
DENTED, OR CRACKED.
Inspect leads for
fraying, burning,
breaks, and/or kinks. If
found, replace probe.
Determine temperature
of water in cookpot
using a thermometer or
pyrometer placed at tip
of probe.
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.
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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
1224
1226
1229
1231
1233
1235
1237
1239
1241
1243
1245
1247
1249
1251
1253
1255
1258
1260
1262
1264
1266
1268
1270
1272
1274
1276
1278
1280
1282
1284
1287
1289
1291
1293
1295
1297
1299
1301
1303
1305
1307
1309
1311
1313
1315
1317
C
F
OHMS
1320
1322
1324
1326
1328
1330
1332
1334
1336
1338
1340
1342
1344
1346
1348
1350
1352
1354
1357
1359
1361
1363
1365
1367
1369
1371
1373
1375
1377
1379
1381
1383
1385
1387
1389
1391
1393
1395
1398
1400
1402
1404
1406
1408
1410
1412
1414
1416
1418
1420
1422
C
85
86
86
87
87
88
88
89
89
90
91
91
92
92
93
93
94
94
95
96
96
97
97
98
F
OHMS
1424
1426
1428
1430
1432
1434
1436
1438
1440
1442
1444
1447
1449
1451
1453
1455
1457
1459
1461
1463
1465
1467
1469
1471
1473
1475
1477
1479
1481
1483
1485
1487
1489
1491
1493
1495
1497
1499
1501
1503
1505
1507
1509
1512
1514
1516
1518
1520
1522
1524
1526
C
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
28
29
29
30
31
31
32
32
33
33
34
34
35
36
36
37
37
38
38
39
39
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
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
113
114
114
115
116
116
117
117
118
118
119
119
120
121
121
122
122
123
123
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
6-17
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6.9
Simplified Wiring Diagrams
6-18
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200-240V
GREEN
BLK
32C
31C
WHT
BLUE
BROWN
LINE
1
6
TEMP PROBE
120 V
T2
T1
BLK 22C
WHT 23C
24V 12V
LOAD
HI LEVEL PROBE
LO LEVEL PROBE
27C
28C
6C
11C
LINE
12C
WHT
27C
4C
J3
BLK
J5
8C
5C
9C
28C
12
11
10
9
5C
8C
4C
7C
SWITCH
15PIN CABLE
TO COMPUTER
2C
8
J4
9C
7
PIN 1
6
BLOWER
5
ORG
13C
7C
4
DUAL SPARK
IGNITION MODULE
2C
3
2
1
29C
PIN 1
J2
43C
16C
55C
30C
BUZZER
PIN 1
16C
J1
IGNITOR CABLE
RIGHT
IGNITOR CABLE
LEFT
INTERFACE BOARD
RIGHT
IGNITOR
HIGH
TEMP
WIRE
SOUND
HIGH
TEMP
WIRE
LEFT
RIGHT
SOLENOID
LEFT
IGNITOR
55C
43C
NOTE:
SENSE 1 & SPARK 1
101C
MUST CONNECT TO THE
SAME IGNITOR. SENSE 2
& SPARK 2 MUST CONNECT
TO THE SAME IGNITOR.
GAS VALVE
8050875F
6-19
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6-20
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FBCR18 & FBKR18 SERIES GAS RETHERMALIZERS
CHAPTER 7: PARTS LIST
7.1
Burner System Components
5
1
2
3
4
ITEM
PART #
COMPONENT
Burner Assemblies
806-5563
806-5564SP
810-1382
Natural Gas, Complete
Propane Gas, Complete
Burner, Reverse Plenum, Universal
Orifice
1
2
810-0916
810-0917
Natural Gas, 3.26mm
Propane Gas, 2.00mm
3
Ignitor and Insulation Kit
826-1714
826-1715
807-1564
823-2528
816-0055
900-5525
810-0507
807-1878
816-0165
Natural Gas
Propane Gas
4
5
*
*
*
*
*
*
*
*
*
*
Blower, Combustion Air, 120V (for 230/240V units, use 807-1712)
Mount, Combustion Air Blower
Insulation, Blower Mount
Bracket, Combustion Air Blower Stabilizer
Spacer, Combustion Air Blower Mount, .23 x .75
Ignitor Wire, 19-inch
Insulation, Ignitor
W82C1SP Flame Sensor Wire
816-0278
810-1353
810-1354
811-0800
Hose, Air, ⅝-inch ID
Flexline, SS, 9-inch
Flexline, SS, 12-inch
Enrichment Tube, 12.5-inch
* Not illustrated.
7-1
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7.2
Cabinetry and Associated Components
3
4
5
18
8
9
6
1
19
10
2
7
11
17
12
20
13
16
14
15
ITEM
PART #
COMPONENT
1
2
806-8060 Cover Assembly w/Handle
810-1374 Handle, Cover
3
910-5246 Bracket, Cover
4
910-5303 Bracket, Cover Support
5
6
7
8
823-2881
900-5737
900-7377
900-5293
816-0158
900-4521
812-1141
900-1552
900-4505
900-7376
900-4504
Flue Cap
Back, Cabinet
Side, Cabinet, CRS (for S/S units, use 910-7377)
Flue Extension, Cabinet Back
Insulation, Upper Cabinet Back
Retainer, Cabinet Back Insulation
Insulation, Cabinet Back
Gusset
Top Brace
Channel, Base Side
Channel, Base Front/Rear
9
10
11
12
13
14
15
16
17
18
19
20
*
806-3853 Door Assembly
810-1442 Handle, Wireform Door
810-0356
810-0357 Caster, 5-inch Wheel, w/Brake
826-0900 Chain Restraint Kit (for units having casters)
826-1095
824-0606
806-5209
826-1043
806-3811
910-8403
Caster, 5-inch Wheel, w/o Brake
Anchor Strap Kit (for units having legs)
Top Cap
Caster Pad/Leg Pad Assembly
Caster/Leg Mounting Hardware Kit
Leg Kit (contains 4 legs)
*
*
*
*
*
Insert, Cookpot Trim (FBKR18 Only)
* Not illustrated.
7-2
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7.3
Computer, Component Box Assembly, and Associated Parts
6
4
3
INTERFACE BOARD MOUNTS
1
ON THESE STUDS
5
NOTE:
Components are not
drawn to scale relative
to each other.
2
7C
29C
2C
8C
Pin 1
7
8
5C
4C
9C
ITEM
PART #
COMPONENT
*
*
*
*
*
*
1
2
3
4
5
6
7
8
106-0769 Computer, CM III (for use on FBCR18 Series rethermalizer only)
806-9352 Computer, CM III (for use on FBKR18 Series rethermalizer only)
806-9295 Interface Board
807-0154 Cordset, 120VAC
809-0349 Spacer, 4mm x 6mm Aluminum Interface Board Standoff
809-0446
Spacer, Ignition Module Standoff
807-2176 Transformer, V/F Dual Voltage
807-1006 Module, 4-Second Honeywell Ignition
807-2659 Switch, Momentary (Manual Fill Switch)
807-1713 Sound Device (Operator Alert)
806-4797 Buzzer Assembly (Ignition Failure Alarm)
810-1164 Terminal Block, 1-piece
806-9286
Harness, 12-pin Wiring
806-2071 Harness, 15-pin Wiring
* Not illustrated.
7-3
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7.4
Cookpot and Associated Parts
ITEM
PART #
COMPONENT
1
Cookpot Assembly (includes flue, insulation, burners and blower)
Natural Gas (for bare cookpot only, order 823-4088SP)
LP (Propane) Gas (for bare cookpot only, order 823-4088SP)
106-2792
106-2793
2
3
4
900-5282 Cover, Front Insulation
816-0270 Insulation, Cookpot Front
816-0144 Insulation, Cookpot Side
900-1762 Retainer, Insulation
5
6
823-2005 Flue
7
8
900-1893 Flue Extension, Cookpot
816-0271 Insulation, Flue
9
900-1894 Flue Extension, Cookpot, Rear
806-7552SP Sensor Assembly, Upper or Lower Water Level
910-5196 Cover, Water Level Sensors
806-4206 Probe Assembly, Temperature
210-0681 Guard, Probe
10
11
12
13
*
814-0048 Sight Glass
*
900-1031 Retainer, Sight Glass
*
*
*
816-0053 Insulation, Sight Glass
816-0145 Insulation, Cookpot Side (14.50” x 3.00”)
816-0166 Insulation, Rear Bottom (17.00” x 3.50”)
*
812-0357
Insulation, Burner (40.00” x 0.62”)
* Not illustrated.
7-4
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7.5
Gas Supply Components
8
9
7
6
5
4
3
2
1
10
15
14
13
11
12
ITEM
PART #
COMPONENT
1
Gas Valve
Natural Gas
LP (Propane) Gas
810-0786
810-0787
2
3
813-0378 Fitting, Cross, ⅛” NPT, Brass
813-0154 Plug, Pipe, ⅛” Hex Head
4
5
6
813-0354
813-0016 Nipple, ⅛” x ¾” NPT, BM
813-0004
Elbow, ⅛” NPT x 90° x ⅛” Tube, Brass
Elbow, ⅛” NPT x 90°, BM
7
8
9
10
11
12
13
14
15
813-0433 Nipple, ⅛” NPT x 2 ½”, BM
813-0304 Bushing, ½” x ¼” Flush, BM
813-0301 Tee, Male, ⅜” x ¼” NPT x ⅜”, Brass
813-0022 Nipple, ½” NPT Close, BM
813-0062
813-0265
823-2766
813-0257
900-1761
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
7-5
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7.6
Plumbing Components
3
2
4
5
8
6
NOTE: Valve handle nut
comes with valve.
7
18
1
17
16
13
10
15
14
12
19
9
11
ITEM
PART #
COMPONENT
1
2
810-1208 Valve, Water Pressure Regulator
810-1351 Vacuum Breaker
3
813-0448 Elbow, ¼”, Brass
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
813-0473 Nipple, ¼” x 4.0”, Brass
813-0471 Nipple, ¼” x 1.5”, Brass
900-2916 Bracket, Water Pressure Regulator Valve
810-1025 Compression Fitting, ¼”, Straight
900-5210 Bracket, Vacuum Breaker
806-5565 Valve Assembly, Solenoid
910-5228 Tubing, Pot to Solenoid, SS
810-1372
813-0202
Fitting, 90°, ¼” NPT x ⅜” Tube
Elbow, 1” NPT x 90°, BM
813-0314 Tee, 1” NPT, BM
813-0525 Fitting, Barbed, 1” NPT Pipe to Hose
809-0374 Clamp, Hose
810-1824 Valve, Drain
910-9527 Handle, Drain Valve
816-0372 Hose, Drain
813-0138 Nipple, Close, 1” NPT
7-6
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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
819-5686
March 2005
SERVICE HOTLINE
1-800-551-8633
PRINTED IN THE UNITED STATES
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