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FGP55 SERIES GAS RETHERMALIZERS

CHAPTER 1: SERVICE PROCEDURES

1-13

1.6.7 Replacing the Cookpot (cont.)

7.

Locate all screws securing back panels. Screw location/orientation will vary according to
rethermalizer model.

8.

Remove back panels on rethermalizer. Retain screws for re-assembly.

9.

Remove screw securing back-
panel brace to flue cap. Support
brace with hand while removing
screw to prevent brace from
falling away. Remove brace and
set aside for reassembly.

Typical back-panel screw locations.

Removing back panel to flue cap brace (arrow).

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Summary of Contents for FGP55 Series

Page 1: ...l Food Equipment Service Association recommends using CFESA Certified Technicians www frymaster com 24 Hour Service Hotline 1 800 551 8633 Email service frymaster com OCTOBER 2006 8196250 NON CE FGP55...

Page 2: ...irectly from Frymaster Dean or any of its authorized service centers and or the part being used is modified from its original configuration this warranty will be void Further Frymaster Dean and its af...

Page 3: ...to cause cancer Inhalation of carbon monoxide is known to the State of California to cause birth defects or other reproductive harm WARNING Do not bang rethermalizer baskets or other utensils on the r...

Page 4: ...3 1 5 Adjusting the Pilot Flame 1 4 1 6 Replacing Rethermalizer Components 1 5 1 7 Troubleshooting and Problem Isolation 1 20 1 8 Troubleshooting Guides 1 26 1 8 Probe Resistance Chart 1 29 1 10 Wiri...

Page 5: ...stem Current units are configured with an electronic standing pilot system Pilot System Configuration In older units a pilot system comprised of the pilot orifice pilot hood and a thermopile were used...

Page 6: ...e cookpot When the programmed setpoint temperature is reached resistance in the probe causes the heat cycle circuitry in the controller to interrupt current flow through the heat relay This in turn in...

Page 7: ...ch restraining devices and plug in the electrical cords 1 3 Cleaning the Gas Valve Vent Tube if applicable 1 Set the rethermalizer power switch and the gas valve to the OFF position 2 Carefully unscre...

Page 8: ...just burner gas pressure remove the cap from the gas valve regulator and adjust to correct pressure 6 Place the rethermalizer power switch and the gas valve in the OFF position Remove the pressure mea...

Page 9: ...will swing open from the top 3 Unplug the rethermalizer wiring harness and ground wire from the back of the computer If replacing the solid state relays disconnect the wires and replace the faulty re...

Page 10: ...ature probe Lift door up disengage rod from lower door bracket and then remove door 4 Disconnect the probe harness connector arrow Use a pin pusher to remove plug from probe wires probe side only Reta...

Page 11: ...according to rethermalizer model Retain mounting hardware for installation of new temperature probe 8 Carefully remove the probe from the cookpot As the probe is removed tilt the probe at an angle to...

Page 12: ...Remove rethermalizer door for easier access see Section 1 6 3 Step 3 for more detail 4 Remove two screws securing the high limit mounting bracket Do not disconnect wires from high limit at this time 5...

Page 13: ...tain mounting hardware for installation of new high limit 7 Carefully pull high limit capillary tube and bulb out of the cookpot from the bottom Remove high limit mounting hardware Retain mounting har...

Page 14: ...IMPORTANT When installing new high limit or backup thermostat ensure the capillary tube and bulb are positioned properly with the mounting hardware installed prior to tightening the compression nut O...

Page 15: ...Drain the cookpot or remove the handle from the drain valve before proceeding further 1 Disconnect rethermalizer from electrical and gas supplies 2 Disconnect the wires from the gas valve terminal bl...

Page 16: ...to moving rethermalizer DANGER Hot water will cause severe burns Never attempt to move this appliance when filled with hot water or to transfer hot water from one container to another 2 Turn gas valv...

Page 17: ...will vary according to rethermalizer model 8 Remove back panels on rethermalizer Retain screws for re assembly 9 Remove screw securing back panel brace to flue cap Support brace with hand while remov...

Page 18: ...flue is removed Step 12 Use a screwdriver or similar tool to free flue cap from cookpots Remove flue cap by lifting up and off of rethermalizer 11 Remove gas manifold pipe for access to gas manifold...

Page 19: ...burners to the burner support rail NOTE On most rethermalizers do not remove bolts from burners Some rethermalizers have an additional bracket that warrants removal of the burner bolts 14 Lift each b...

Page 20: ...rners is unique in the flame transfer hole configuration and must be reinstalled correctly Left burners L Flame transfer hole is on the right side of the burner head Center burners C Flame transfer ho...

Page 21: ...cribed in Step 15 then remove trailing pilot 16 Remove cotter pin from drain valve linkage then disconnect actuator rod from drain valve actuator 17 Remove the temperature probe from cookpot see Secti...

Page 22: ...r by lifting up and out 24 Position the cookpot upside down on a suitable work surface 25 Record position of the valve stem in relation to the cookpot prior to removing the drain valve Using a suitabl...

Page 23: ...FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1 SERVICE PROCEDURES 1 19 1 6 8 Annotated Cookpot Bottom...

Page 24: ...tion Failures Ignition failure occurs when the ignition module fails to sense a flame within the 60 second time delay period and locks out Turn the rethermalizer off locate and fix the problem then tu...

Page 25: ...or pilot system it is most likely in the gas valve itself but before replacing the gas valve refer to the troubleshooting guides in this chapter 1 7 2 Improper Burner Functioning With problems in this...

Page 26: ...is an insufficient air supply or drafts that are blowing the pilot flame away from the burner Check for negative pressure conditions in the kitchen area If air is flowing into the kitchen area this i...

Page 27: ...ure is not the cause check for high burner manifold gas pressure in accordance with the procedures in Section 1 4 An obstructed flue which prevents the rethermalizer from properly exhausting may also...

Page 28: ...d corrective actions are 1 Rethermalizer constantly displays Cause Setpoint incorrect or missing Corrective Action Press 1 6 5 0 enter the correct setpoint using keypad then press to lock in the setpo...

Page 29: ...with Loctite PST567 sealant or equivalent to prevent leakage In very rare cases a leak may develop along one of the welded edges of the cookpot or where the tube is welded to the cookpot When this oc...

Page 30: ...is functioning Make sure float is moving freely up and down and does not have a starch build up and that the shaft is not bent Replace float switch if defective B Failed computer B Replace the comput...

Page 31: ...SC Display shows heating indicator cycles on and off normally but burners will not light A Failed computer A If available substitute a computer known to be working for the suspect computer If the reth...

Page 32: ...align flame sensor Check flame sensor for loose wires B Pilot stays lit and the high limit and flame sensor is working but burners fail to light C Inspect gas valve and replace if defective D Gas valv...

Page 33: ...2 285 1524 141 355 1664 179 80 1101 27 150 1247 66 220 1391 104 290 1534 143 360 1674 182 85 1112 29 155 1258 68 225 1402 107 295 1544 146 365 1684 185 90 1122 32 160 1268 71 230 1412 110 300 1554 149...

Page 34: ...is section depict wiring as of the date of manual publication It may not reflect design changes made to the equipment after publication Refer to the wiring diagram affixed to the unit when actually tr...

Page 35: ...FGP55 SERIES GAS RETHERMALIZERS CHAPTER 1 SERVICE PROCEDURES 1 31 1 10 2 Wiring Diagram FGP255 w Electronic Standing Pilot without Interface Board...

Page 36: ...U BLK ORG RED NC NO YEL SSR1 POWER BLU BLK THERMOCOUPLE GAS VALVE WHT 1 2 1 2 BLK 2 V 1 V 3 V 4 V 5 V 6 V 7 V WHT BLK RED YEL NC NO SSR2 WATER 120 VAC 13 9 V 8 V 10 V 12 11 V V V V 14 V 15 2 Amp Fuse...

Page 37: ...BLK WHT BLU SOLENOID VALVE HIGH LIMIT 1 2 1 2 SOUND DEVICE N O FLOAT SWITCH J5 HI LO J3 K6 K3 15V GND J1 K1 K2 K5 K4 J2 J4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 RED BLK BLU YE...

Page 38: ...FGP55 SERIES GAS RETHERMALIZERS CHAPTER 2 PARTS LIST 2 1 2 1 FGP55 Primary Components...

Page 39: ...810 2150 Burner Right Side Cast Iron 11 823 3248 Leg Support Assembly 12 807 3552 Gas Valve Natural Gas Electronic Ignition 24 VAC 807 3628 Gas Valve LP Gas Electronic Ignition 24 VAC 810 2156 Gas Va...

Page 40: ...es item 29 27 826 1117 Caster 5 inch w o Brake Kit includes washers and screws 28 826 1118 Caster 5 inch with Brake Kit includes washers and screws 29 810 1374 Handle FGP55 Cover 30 807 3593 Cord set...

Page 41: ...RIES RETHERMALIZERS CHAPTER 2 PARTS LIST 2 4 2 2 Components and Controllers Components are applicable to all FGP55 rethermalizers covered in this manual unless otherwise noted 1 2 3 4 7 6 8 9 10 11 12...

Page 42: ...or Honeywell Valves Only CE ONLY 810 2398 ECO Connector Robertshaw Valves Only CE ONLY 7 106 2361SP Probe Assembly RTD Temperature Dean Computer 106 0987 Harness Wire Temp Probe 809 0888 Clip Tinnerma...

Page 43: ...2 807 3793 Switch High Level 3 813 0805 Coupling inch NPT SS 4 813 0806 Nipple inch NPT x 1 SS 5 813 0807 Bushing inch NPT x inch NPT SS 6 813 0619 Flareless Male Tube Connection SS 7 826 2146 Switch...

Page 44: ...824 0967 Wireway Weldment FGP55 Control Panel 2 807 0800 Transformer 120V 50 60HZ 50VA 24VAC 3 807 0855 Transformer 120V 50 60HZ 20VA 12VAC 4 900 8715 Relay Bracket 5 826 1733 Relay Solid State 18AMP...

Page 45: ...325 for Boston Market 3 806 8007 Assembly Component Box 4 806 9295 Controller PCB Water Board used on older units 5 807 2176 Transformer V T Dual Voltage 6 806 4797 Buzzer Assembly 7 807 3366 Module H...

Page 46: ...S SS 2 813 0773 Elbow inch x 90 SS 3 813 0815 Nipple inch x 2 inch SS 4 810 2419 Valve Check inch NPT 5 813 0807 Bushing inch NPT x inch NPT SS 6 813 0806 Nipple inch NPT x 1 inch SS 7 807 3635 Soleno...

Page 47: ...Valve Handle Red 4 210 3596 Bracket Handle Locator 5 813 0802 Tee 1 inch SS 6 813 0814 Bushing 1 inch x inch Galv 7 813 0812 Nipple inch NPT x 9 inch SS 8 813 0803 Union inch NPT SS 9 813 0804 Nipple...

Page 48: ...0 inch BM 7 Valve Gas See item 12 on page 2 2 8 813 0247 Nipple inch NPT x 3 50 inch BM 9 813 0062 Elbow inch x 90 BM 10 813 0751 Nipple inch NPT x 27 00 inch BM 11 106 5640 Manifold Assembly Rear Gas...

Page 49: ...6 x inch Phillips Head NP 809 0359 Screw 8 x inch Hex Washer Head 809 0360 Screw 8 x inch Hex Washer Slot Head 826 1371 Screw 8 x inch Hex Head ZP Pkg of 25 809 0361 809 0818 Screw 8 x inch Type B 80...

Page 50: ...rt Louisiana 71135 1000 Shipping Address 8700 Line Avenue Shreveport Louisiana 71106 TEL 1 318 865 1711 FAX Parts 1 310 327 3343 FAX Tech Support 1 318 219 7135 PRINTED IN THE UNITED STATES SERVICE HO...

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