Dean FPD65 Instruction manual

FPD65 Series with Built-In Filtration

PARTS LIST

INCLUDED

Frymaster, a member of the Commercial Food Equipment Service Association, recommends using CFESA Certified Technicians.

24-Hour Service Hotline 1-800-551-8633 SEPT 2008

*8196039*

Please read all sections of this manual and retain for future reference.

NOTICE

This appliance is intended for professional use only and is to be operated by qualified personnel only. A Frymaster/Dean Factory Authorized Service Center (FASC) or other qualified professional should perform installation, maintenance, and repairs. Installation, maintenance, or repairs by unqualified personnel may void the manufacturer’s warranty. See Chapter 1 of this manual for definitions of qualified personnel.

NOTICE

This equipment must be installed in accordance with the appropriate national and local codes of the country and/or region in which the appliance is installed. See NATIONAL CODE

REQUIREMENTS in Chapter 3 of this manual for specifics.

NOTICE

Drawings and photos used in this manual are intended to illustrate operational, cleaning and technical procedures and may not conform to onsite management operational procedures.

NOTICE TO OWNERS OF UNITS EQUIPPED WITH COMPUTERS

U.S.

This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: 1) This device may not cause harmful interference, and 2) This device must accept any interference received, including interference that may cause undesired operation. While this device is a verified Class A device, it has been shown to meet Class B limits.

CANADA

This digital apparatus does not exceed the Class A or B limits for radio noise emissions as set out by the ICES-003 standard of the Canadian Department of Communications.

Cet appareil numerique n’emet pas de bruits radioelectriques depassany les limites de classe A et B prescrites dans la norme NMB-003 edictee par le Ministre des Communications du Canada.

NOTICE

IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART FOR THIS ENODIS

EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART PURCHASED

DIRECTLY FROM FRYMASTER/DEAN, OR ANY OF ITS AUTHORIZED SERVICE CENTERS,

AND/OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL CONFIGURATION, THIS

WARRANTY WILL BE VOID. FURTHER, FRYMASTER/DEAN AND ITS AFFILIATES WILL NOT BE

LIABLE FOR ANY CLAIMS, DAMAGES OR EXPENSES INCURRED BY THE CUSTOMER WHICH

ARISE DIRECTLY OR INDIRECTLY, IN WHOLE OR IN PART, DUE TO THE INSTALLATION OF

ANY MODIFIED PART AND/OR PART RECEIVED FROM AN UNAUTHORIZED SERVICE CENTER.

NOTICE

The Commonwealth of Massachusetts requires any and all gas products to be installed by a licensed plumber or pipe fitter.

DANGER

Improper installation, adjustment, maintenance or service, and unauthorized alterations or modifications can cause property damage, injury, or death. Read the installation, operating and service instructions thoroughly before installing or servicing this equipment. Only qualified service personnel may convert this appliance to use a gas other than that for which it was originally configured. See Chapter 1 of this manual for definition of qualified service personnel.

DANGER

Adequate means must be provided to limit the movement of this appliance without depending upon the gas line connection. Single fryers equipped with legs must be stabilized by installing anchor straps. All fryers equipped with casters must be stabilized by installing restraining chains. If a flexible gas line is used, an additional restraining cable must be connected at all times when the fryer is in use.

DANGER

The front ledge of the fryer is not a step. Do not stand on the fryer. Serious injury can result from slips or contact with the hot oil.

DANGER

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

DANGER

Instructions to be followed in the event the operator smells gas or otherwise detects a gas leak must be posted in a prominent location. This information can be obtained from the local gas company or gas supplier.

DANGER

The crumb tray in fryers equipped with a filter system must be emptied into a fireproof container at the end of frying operations each day. Some food particles can spontaneously combust if left soaking in certain shortening material. Additional information can be obtained in the filtration manual included with the system.

WARNING

No structural material on the fryer should be altered or removed to accommodate placement of the fryer under a hood. Questions? Call the Frymaster/Dean Service Hotline at 1-800-551-8633.

WARNING

Do not bang fry baskets or other utensils on the fryer’s joiner strip. The strip is present to seal the joint between the frypot. Banging fry baskets on the strip to dislodge shortening will distort the strip, adversely affecting its fit. It is designed for a tight fit and should only be removed for cleaning.

FPD65 Series Gas Fryers

Installation & Operation Manual

1. INTRODUCTION

TABLE OF CONTENTS

2. IMPORTANT INFORMATION

2.1 Receiving and Unpacking Equipment

2.2 General

2.3 Principles of Operation

2.5 Pre-Installation

2.6 Air Supply and Ventilation

2.7 Equipment Installed at High Altitudes

3. INSTALLATION

3.1 Installing the Fryer

4. FRYER OPERATIONS

2-3

2-3

2-5

2-5

2-1

2-1

2-2

2-3

Page #

1-1

1-1

1-1

1-1

1-1

1-2

1-3

4-1

4-1

4-3

4-5

3-1

3-1

3-4

3-7

3-9

FPD65 Series Gas Fryers

Installation & Operation Manual

TABLE OF CONTENTS (CONT.)

5. FILTRATION OPERATION

5.1 General

5.3 Daily Filtration Operation

5.4 Operating the Filter

6. PREVENTATIVE MAINTENANCE

6.1 General

7. TROUBLESHOOTING

7.1 General

7.2 Pilot Burner Malfunction

7.3 Main Burner Malfunctions

7.4 Wiring Diagram, Main

7.5 Wiring Diagram, Filter

8. PARTS LIST

8.1 Cabinetry and Related Components

8.2 Doors, Topcaps and Related Components

8.3 Frypots, Burners and Related Components

8.5 Filter Pan and Related Components

8.7 Oil-Return Components

8.8 Suction Tube, Oil-Return Components

Page #

5-1

5-1

5-1

5-4

5-6

6-1

6-1

7-1

7-1

7-2

7-2

7-4

7-5

8-1

8-1

8-3

8-4

8-6

8-7

8-8

8-10

8-11

FRYMASTER FPD65 SERIES GAS FRYERS

CHAPTER 1: INTRODUCTION

1.1 After Purchase

In order to improve service, have the following chart filled in by the Frymaster/Dean Authorized

Service Technician who installed this equipment.

Authorized Service

Technician/FASC

Address

Telephone/Fax

Model Number

Serial Number

Gas Type

1.2 Ordering Parts

Customers may order parts directly from their local factory authorized service center. For this address and phone number, contact your factory authorized service center or call the Frymaster/Dean

Service Hotline phone number, 1-800-551-8633.

To speed up your order, provide the model number, serial number, gas type, part needed, item part number (if known), and quantity needed.

1.3 Service Information

Call the Frymaster/Dean Service Hotline, 1-800-551-8633, for the location of your nearest factory authorized service center. To assist you more efficiently, always provide the service technician with the model number, gas type, serial number, and the nature of the problem.

1.4 Computer Information

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. While this device is a verified Class A device, it has 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 environment. 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 communications. 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/her own expense.

1-1



1.4 Computer Information (cont.)

The user is cautioned that any changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment.

If necessary, the user should consult the dealer or an experienced radio and television technician for additional suggestions.

The user may find the following booklet prepared by the Federal Communications Commission helpful: "How to Identify and Resolve Radio-TV Interference Problems". This booklet is available from the U.S. Government Printing Office, Washington, DC 20402, Stock No. 004-000-00345-4.

1.5 Safety Information

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

Throughout this manual, you will find notations enclosed in double-bordered boxes similar to the ones below.

CAUTION

CAUTION boxes contain information about actions or conditions that may cause or result in a

malfunction of your system.

WARNING

WARNING boxes contain information about actions or conditions that may cause or result in

damage to your system, and which may cause your system to malfunction.

DANGER

DANGER boxes contain information about actions or conditions that may cause or result in injury

to personnel, and which may cause damage to your system and/or cause your system to malfunction.

1-2



1.6 Service Personnel

1.6.1 Definitions

A. Qualified and/or Authorized Operating Personnel

1. Qualified/authorized operating personnel are those who have carefully read the information in this manual and have familiarized themselves with the equipment functions, or have had previous experience with the operation of equipment covered in this manual.

B. Qualified Installation Personnel

1. 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 gas-fired appliances. Qualified personnel must be experienced in such work, be familiar with all gas precautions involved, and have complied with all requirements of applicable national and local codes.

C. Qualified Service Personnel

1. Qualified service personnel are those who are familiar with Frymaster/Dean equipment and have been authorized by Frymaster/Dean to perform service on Frymaster/Dean equipment.

All authorized service personnel are required to be equipped with a complete set of service parts manuals and stock a minimum amount of parts for Frymaster/Dean equipment. A list of Frymaster/Dean Factory Authorized Service Centers (FASCs) was included with the fryer when shipped from the factory. Failure to use qualified service personnel will void the

Frymaster/Dean warranty on your equipment.

1-3


CHAPTER 2: IMPORTANT INFORMATION

2.1 Receiving and Unpacking Equipment

A. Check that the containers are upright. Use an outward prying motion - no hammering - to remove the cartons. Unpack fryers carefully and remove all accessories from the carton and/or frypots. Do not discard or misplace accessories, as they will be needed during final assembly and fryer operation.

B. After unpacking, immediately check the equipment for visible signs of shipping damage. If damage has occurred, contact the carrier and file the appropriate freight claims. Do not contact the factory. Shipping damage responsibility is between the carrier and the dealer.

If your equipment arrives damaged:

1. File claim for damages immediately, regardless of extent of damage.

2. Visible loss or damage: Be sure this is noted on the freight bill or express receipt and is signed by the person making the delivery.

3. Concealed loss or damage: If damage is unnoticed until equipment is unpacked, notify freight company or carrier immediately, and file a concealed damage claim. This should be done within 15 days of date of delivery. Be sure to retain container and all packing materials for inspection.

NOTE: Frymaster/Dean Does Not Assume Responsibility for Damage or Loss Incurred

in Transit.

C. Built-in filtration cabinet: Remove the filter pan from the cabinet before removing system from pallet.

D. Five- and Six-battery Frying Systems: Units are shipped on two pallets. Casters are preinstalled on the frying system and unloading ramps are furnished to facilitate removal of the units off the pallets. Remove pallet supports from underneath fryer and carefully roll the unit down the ramps from the front (cooking side). See assembly instructions shipped with

unit for system assembly.

E. Remove all plastic skin from sides, front, and doors of the fryers. Units are shipped with plastic skin to protect the stainless components from surface damage during shipping.

Failure to remove the plastic prior to initial fryer operation will make it very difficult to remove later.

2-1



2.2 General

Qualified, licensed, and/or authorized installation or service personnel only (as defined in

Section 1.6) should perform the following:

• Installation and service on Frymaster/Dean equipment.

• Conversion of this appliance from one gas type to another.

Failure to use qualified, licensed, and/or authorized installation or service personnel to install, convert to another gas type or otherwise service this equipment will void the Frymaster/Dean 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 code 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.

DANGER

Building codes prohibit a fryer with its open tank of hot oil/shortening from being installed beside an open flame of any type, including those of broilers and ranges.

Upon arrival, inspect the fryer carefully for visible or concealed damage. (See Receiving and

Unpacking Equipment in Section 2.1.)

2.2.1 Product Description

Frymaster FPD65 Series gas fryers are energy efficient, tube-style, gas-fired units. All units are shipped completely assembled with accessories packed inside the frypot. Frymaster FPD65 Series gas fryers are adjusted, tested and inspected at the factory before shipment. The input rates of this model are listed in this manual.

WARNING

The on-site supervisor is responsible for ensuring that operators are made aware of the inherent hazards of operating a hot oil frying system, particularly the aspects of system operation, oil filtration, draining and cleaning procedures.

2-2



2.3 Principles of Operation

The incoming gas flows through orifices and is mixed with air in the burners to create the correct ratio for proper combustion. The mixture is ignited at the front end of each heat tube by the pilot light. Internal diffusers slow the flame as it goes through the burner tube. This slower and more turbulent flame gives much better heat transfer to the walls of the tubes, thereby heating the oil better.

2.4 Rating Plate

This is attached to the inside front door panel. Information provided includes the model and serial number of the fryer, BTU/hr input of the burners, outlet gas pressure in inches W.C. and whether the unit has natural or propane gas orifices.

DANGER

Fryers

MUST be connected ONLY to the gas type identified on the attached rating plate.

2.5 Pre-Installation

DANGER

No structural material on the fryer should be altered or removed to accommodate placement of the fryer under a hood. Questions? Call the Frymaster/Dean Service

Hotline at 1-800-551-8633.

DANGER

Do not connect this appliance to the gas supply before reviewing all information in this chapter.

A. General: Only licensed personnel should install any gas-fired equipment.

1. A manual gas shut-off valve must be installed in the gas supply line ahead of the fryers for safety and ease of future service.

2. Frymaster FPD65 Series gas fryers require 120VAC 60 cycle or 230VAC single-phase 50hertz (International/CE) electrical service and are equipped with a 16-3 SJT grounded flexible power cord for a direct connection to the power supply. Amperage draw for each unit depends on the accessories supplied with the unit/system.

2-3



2.5 Pre-Installation (cont.)

B. Clearances: The fryer area must be kept free and clear of all combustibles. This unit is designcertified for the following installations:

1. Commercial installation only (not for household use).

2. Non-combustible floor installation equipped with factory-supplied 6-inch (15-cm) adjustable legs or 5-inch (13-cm) casters;

3. Combustible construction with a minimum clearance of 6-inches (15-cm) side and 6-inches

(15-cm) rear, and equipped with factory-supplied 5-inch (13-cm) casters.

C. Installation Standards

1. U.S. installations must meet: 2. Canadian installations must meet:

American National Standard Institute

ANSI Z83.11

American Gas Association

8501 E. Pleasant Valley Road

Cleveland, OH 44131

National Electrical Code

ANSI/NFPA #70

American National Standard Institute

1430 Broadway

New York, NY 10018

NFPA Standards #96 and #211

National Fire Protection Association

470 Atlantic Avenue

Boston, MA 02110

CAN 1-B149 Installation Codes

Canadian Gas Association

55 Scarsdale Road

Don Mills, ONT, M3B 2R3

Canadian Electric Code c22.1, part 1

Canadian Standards Association

178 Rexdale Blvd.

Rexdale, ONT, M9W 1R3

2-4



2.6 Air Supply and Ventilation

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.

Keep the area around the fryer clear to prevent obstruction of combustion and ventilation airflow as well as for service and maintenance.

A. Do not connect this fryer to an exhaust duct.

B. Correct installation and adjustment will ensure adequate airflow to the fryer system.

C. A commercial, heavy-duty fryer must vent its combustion wastes to the outside of the building. A deep-fat fryer must be installed under a powered exhaust hood, or an exhaust fan must be provided in the wall above the unit, as exhaust gas temperatures are approximately

800-1000°F (427-538°C). Check air movement during installation. Strong exhaust fans in the exhaust hood or in the overall air conditioning system can produce slight air drafts in the room.

D. Do not place the fryer’s flue outlet directly into the plenum of the hood, as it will affect the gas combustion of the fryer.

E. Never use the interior of the fryer cabinet for storage or store items on shelving over or behind the fryer. Exhaust temperatures can exceed 800°F (427°C) and may damage or melt items stored in or near the fryer.

F. Adequate distance must be maintained from the flue outlet of the fryer(s) to the lower edge of the filter bank. Per NFPA Standards No. 96, a minimum of 18-inches (45-cm) should be maintained between the flue(s) and the lower edge of the exhaust hood filter.

G. Filters and drip troughs should be part of any industrial hood, but consult local codes before constructing and installing any hood. The duct system, the exhaust hood and the filter bank must be cleaned on a regular basis and kept free of grease.

2.7 Equipment Installed at High Altitudes

A. The fryer input rating (BTU/hr) is for elevations up to 2,000 feet (610-m). For elevations above 2,000 feet (610-m), the rating should be reduced four percent for each additional 1,000 feet (305-m) above sea level.

B. The correct orifices are installed at the factory if operating altitude is known at time of the customer’s order.

2-5


CHAPTER 3: INSTALLATION

3.1 Installing the Fryer

Decathlon 65 Series fryer systems are shipped in sections. The fryers are uncrated, removed from pallets and assembled together. Important aspects during assembly include aligning and connecting the drain system, oil return system, rinse-line system (where applicable), oil-return switch wiring harness and fryer cabinets. Slight modifications to connecting hardware may be required when assembling the system. The instructions below provide step-by-step instructions to assist the installer in assembly. For this procedure, the fryers are numbered from right to left as follows:

Fryers #1, #2, #3, #4, #5 and #6 (where applicable).

1. Open the doors of the filtration fryer cabinet.

Remove filter pan from the cabinet. Uncrate fryers and remove the pallet supports. Install ramps and slowly roll the fryer(s) off the pallets.

2. Remove door from fryers to be connected by lifting the door upward and removing the door pin from the bottom hinge. Remove slip-nuts from drain-tees on fryers being connected, lubricate O-rings with vegetable oil and install on drainpipe (Fig. 2). Use care not to damage the slip-nut O-rings when installing slip-nut on

drainpipe. Insert the drainpipe into the fryer drain-tee (Fig. 3). Screw slip-nut onto the tee but do not tighten at this time. Position fryers being connected within 6 inches of each other, near the permanent installation area. Guide the drainpipe through the opposite fryer cabinet opening as the cabinets are positioned.

NOTE: When the slip nuts are tightened, the

"blue" marks on each end of the drainpipe should align to the outside edge of each slip nut.

Figure 1. Remove pallet supports (arrow) before removing fryers from pallets.

Properly align the drainpipe evenly between the two drain-tees using the "blue" marks on the tube ends to prevent leaks and/or blocked drain valves.

Figure 2. Slip-nut/drainpipe detail.

3-1

Figure 3. Insert drainpipe section into fryer drain-tee before pushing fryers together

(arrow). Do this as required for all cabinets being assembled.



3.1 Installing the Fryer (cont.)

3. Connect red/white or red/yellow wires (Figure 4, left) between fryer sections being assembled

(Figure 4, right, arrow). Oil-return will not operate properly if these wires are not connected.

NOTE: On systems shipped in three or more sections, additional wiring between cabinets will exist. Ensure all wires are connected before completing cabinet assembly.

4. Remove the lower back panel-strips on fryers being assembled to gain access to the oil return and rinse-line connections (Figure 5, arrows).

Back removal may not be required on some systems.

5. Slowly push the two cabinets together. Ensure the drainpipe and slip-nut are aligned with the drain-tee on the opposite fryer section. Ensure the oil-return and rinse-hose connections (where applicable) on each fryer section are aligned.

Ensure oil-return switch wires between cabinet sections are not pinched when the cabinets are brought together. Pull excess wire through the opposite fryer side as the cabinets are brought together. Secure excess wire inside cabinet with a wire tie.

6. With the cabinets together, insert the drainpipe into the opposite fryer drain-tee and position it evenly between the fryers being connected.

Connect the oil-return and rinse-lines by accessing the oil return union through the lower fryer-back openings. Connect all fittings, but do not tighten at this time.

7. Align the cabinet connection holes, front and back (Figure 6, arrow). Connection hardware is included in the accessories pack. Insert bolts and install nuts, but do not tighten. If holes do not align, use a 3/16" drill-bit and drill through the misaligned hole.

8. Install the frypot joiner strip between cabinet sections (Figure 7; also see factory-installed strips on two-battery cabinet sections).

Figure 4. Oil return wires between sections must be connected for oil-return operation.

Figure 5. Oil return and rinse-line (where applicable) connections.

Figure 6. Cabinet connection locations inside cabinet sections (front shown).

Figure 7. Install joiner strip(s) after fryers are connected.

3-2




9. Install the front connecting post on the connected cabinets (Figure 8; see factory-installed posts on two-battery fryer sections).

10. Complete installation of topcap battering strips after the front connecting post has been installed

(Figure 9).

NOTE: Systems shipped in three or more sections will require the installation of topcaps and other components prior to installing topcap-battering strips. See Topcap

Installation Instructions for these systems.

11. Install the rear connecting plate (Figure 10).

Remove four screws from the cabinet backs

(Figure 10, arrows), install connecting plate and replace screws. Connection strips vary from system to system.

12. At the fryer front: Tighten the drain manifold slip-nuts. Install doors removed at the beginning of assembly. At the fryer back: Tighten the oilreturn line and rinse-line (where applicable) union(s).

13. Reinstall filter pan after fryer start-up has been performed (boil-out, burner adjustment, etc.)

NEVER ALLOW WATER OR BOILOUT

SOLUTION INTO FILTER SYSTEM.

Check all connections for leaks. Ensure all

components operate properly.

Figure 8. Installing front connecting post on connected fryer sections.

Figure 9. Complete installation of topcap battering strips (arrow) after installing front connecting post(s) on connected fryers.

Figure 10. Install rear connecting plate.

3-3




DANGER

Fryers must be at room temperature and empty of oil during movement to avoid damage and possible bodily injury.

DANGER

Hot shortening can cause severe burns. Avoid contact. Under all circumstances, oil must be removed from the fryer before attempting to move it to avoid oil spills, and the falls and severe burns that could occur. This fryer may tip and cause personal injury if not secured in a stationary position.

3.2 Gas Connections

DANGER

Before connecting new pipe to this appliance the pipe must be blown out thoroughly to remove all foreign material. Foreign material in the burner and gas controls will cause improper and dangerous operation.

NATIONAL CODE REQUIREMENTS

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

Officials 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.

Notice

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.

DANGER

The fryer

MUST be connected to the gas supply specified on the rating and serial number plate located on the back of the fryer door.

3-4



3.2 Gas Connections (cont.)

DANGER

If gas odors are detected, the gas supply MUST be shut off at the main shut-off valve. The local gas company or FASC should be contacted immediately to rectify the problem.

A. The gas supply (service) line must be the same size or greater than the fryer inlet line. This fryer system is equipped with three 1" (28 mm) female inlets (one inlet per two fryers). The gas supply line must be sized to accommodate all the gas-fired equipment that may be connected to that gas supply. Consult your contractor, gas company, supplier, or other knowledgeable authorities.

Recommended Gas Supply Line Sizes

Gas Types

Natural Gas

1

3/4" (22 mm)

Number of Fryers

2 to 3

1" (28 mm)

4 or more (*)

1-1/4" (35 mm)

Propane Gas 1/2" (15 mm) 3/4" (22 mm) 1" (28 mm)

(*) When exceeding 18 feet for a configuration of more than four fryers, it is necessary to provide a 1-1/4" (35 mm) rigid gas connection.

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 lighting 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 frypot and can cause a fire. Always ensure that melted shortening, cooking oil or water is in the frypot before firing the unit.

B. Rigid Connections: Check any installer-supplied intake pipe(s) visually and clean threading chips, or any other foreign matter before installing into a service line. If the intake pipes are not clear of all foreign matter, the orifices will clog when gas pressure is applied. Seal pipe joints with a sealant resistive to LP gas. When using thread compound on gas piping, use very small amounts and only on male threads. Use a pipe thread compound that is not affected by the chemical action of LP gases. DO NOT apply thread compound to the first two pipe threads—doing so will cause clogging of the burner orifices and control valve.

3-5




C. Manual shut-off valve: This gas service supplier-installed valve must be installed in the gas service line ahead of the fryers in the gas stream and in a position where it can be reached quickly in the event of an emergency.

D. Regulating Gas Pressure: The fryer and shut-off valve must be disconnected from the gas supply during any pressure testing of the system.

1. External gas regulators are not normally required on this fryer. A safety control valve protects the fryer against pressure fluctuations. If the incoming pressure is in excess of

½" PSI (3.45 kPa/35 mbar), a step-down regulator will be required.

DANGER

When pressure-testing incoming gas supply lines, disconnect the fryer from the gas line if the test pressure is ½" PSI [3.45 kPa (14 inches W.C.)] or greater to avoid damage to the fryer’s gas piping and gas valve(s).

E. Manifold Pressure: Your local service technician should check the manifold pressure with a manometer.

1. Check the rating plate for specific manifold gas pressures. Natural gas units normally require 4" W.C., and propane units normally require 11" W.C. gas pressure.

2. Double check the arrow forged into the bottom of the regulator body, which shows gas flow direction. It should point downstream towards the fryers. The air vent cap is also part of the regulator and should not be removed.

3. If a vent line from the gas pressure regulator is used, it should be installed in accordance with local codes or in the absence of local codes, with the National Fuel

Gas Code, ANSI Z223.1-(latest edition).

WARNING

Use a diluted soap solution to find potentially dangerous gas leaks when making new connections.

F. Regulators can be adjusted in the field, but it is recommended that they not be unless the part is known to be out of adjustment or serious pressure fluctuations are found to exist and can be solved no other way.

G. Only qualified service personnel should make adjustments to the regulators.

H. Orifices: The fryer can be configured to operate on any available gas. The correct safety control valve, appropriate gas orifices, and pilot burner are installed at the factory. While the valve can be adjusted in the field, only qualified service personnel should make any adjustments with the proper test equipment.

3-6




I. Flexible Couplings, Connectors and Casters:

1. If the fryer is to be installed with flexible couplings and/or quick-disconnect fittings, the installer must use a heavy-duty AGA design-certified commercial flexible connector of at least 1" NPT (with suitable strain reliefs), in compliance with the Standard for

Connectors for Movable Gas Appliances, ANSI Z21.69-(latest edition) and Addenda

Z21.69a-(latest edition). Quick disconnect devices must comply with the Standard for

Quick-Disconnect Devices for Use with Gas Fuel, ANSI Z21.41-(latest edition).

WARNING

Do not attach accessories to this fryer unless fryer is secured from tipping.

Personal injury may result.

2. The fryer must be restrained by means independent of the flexible coupling or connector in order to limit the movement of the fryer. Clips are located on the back panel of the fryer for the attachment of restraints.

3. If disconnection of the restraint is necessary, this restraint must be reconnected after the fryer has been returned to its originally installed position.

J. After hook-up, bleed the gas line of air to ensure that the pilot light will ignite quickly.

3.3 Adjustments/Adaptation To Different Gases

A. Proper operation of Frymaster/Dean gas fryers requires operator to inspect the following adjustments in terms of:

1. Gas inputs and pressures.

2. Voltage and polarities of electrical power supplies.

B. Frymaster/Dean gas fryers are manufactured to use the type of gas and pressure specified on the rating plate. When changing to a different gas, adaptation must be performed by

qualified personnel. Failure to use qualified personnel will void the Frymaster/Dean warranty.

3-7



3.3.1 Specifications

3.3.1.1 Adjustments to Different Gas Types

Gas Adjustments

Gas Type Natural LP

Manifold Pressure† 4" W.C.*/10 mbar* 11" W.C.*/27.5 mbar*

Orifice Diameter

Burner Marking

Model Specific Model Specific

None None

Pilot Marking 26N (P/N 810-0811) 16LP (P/N 810-2400)

* Gas pressure may vary per fryer model and altitude. Check the rating plate for specific

gas pressures.

NOTE: Outlet gas pressure must be adjusted strictly within the above requirements 5 to 10 minutes after the appliance is operating.

† For controls and adjustments, please refer to the "gas valve" illustration on page 3-9. (Pilot Flame

Adjustment: Turn the pilot adjustment screw clockwise/counter-clockwise until the desired flamevolume is achieved.)

3.3.2 Gas Conversion Procedures

DANGER

This appliance was configured at the factory for a specific type of gas. Converting from one gas type to another requires the installation of specific gas-conversion components.

Switching to a different type of gas without installing the proper conversion components 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.

3-8



3.3.2 Gas Conversion Procedures (cont.)

Contact factory with the following information when performing conversions:

• Fryer Serial Number

• Fryer Model Number

• Gas Type

• Operating Altitude

Conversions can only be executed by qualified, factory-authorized personnel.

Pilot pressure adjustment

(remove cover screw to access)

Pressure flow adjustment

(remove cover screw to access)

Typical gas valve

Regulator Vent

Pilot gas supply connection.

ON/OFF Gas-Cock Knob

3.4 Electrical Connections

The fryer when installed must be electrically grounded in accordance with local codes, or in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70-(latest edition).

DANGER

This fryer is equipped with three-prong (grounding) plugs for 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

PRONGS ON THESE PLUGS!

The rating plate and wiring diagram are located inside the front door. The fryer is equipped with a

120VAC single-phase 60-hertz system (Domestic), or 230VAC single-phase 50-hertz system

(International/CE). Do not cut or remove the ground prong from any of the power cord plugs. Do not attempt to use the fryer during a power outage.

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.

3-9


CHAPTER 4: FRYER OPERATIONS

4.1 Initial Start-up

WARNING

The on-site supervisor is responsible for ensuring that operators are made aware of the inherent hazards of operating a hot oil frying system, particularly the aspects of system operation, oil filtration, draining and cleaning procedures.

Cleaning: New units are wiped clean with solvents at the factory to remove any visible signs of dirt, oil, grease, etc. remaining from the manufacturing process, then coated lightly with oil. Before any food preparation, wash thoroughly with hot, soapy water to remove any film residue and dust or debris then rinse out and wipe dry. Also wash any accessories shipped with the unit. Close the drain valve completely and remove the crumb screen covering the heating tubes. Ensure the screws holding the thermostat and high-limit control sensing bulbs into the frypot are tight.

Typical high-limit/sensor probe locations and mounting hardware.

WARNING

Do not bang fry baskets or other utensils on the fryer’s joiner strip. The strip is present to seal the joint between the frypot. Banging fry baskets on the strip to dislodge shortening will distort the strip, adversely affecting its fit. It is designed for a tight fit and should only be removed for cleaning.

DANGER

Never operate this appliance with an empty frypot. The frypot must be filled with water or cooking oil/shortening before lighting the burners. Failure to do so will damage the frypot and may cause a fire.

WARNING

When checking for burner ignition or performance, do not get too close to the burners. Slow ignition can cause possible flashback, increasing the potential for facial and body burns.

4-1



4.1.1 Pilot Lighting Procedures, Electronic Ignition Systems

Initial Pilot Lighting: All Frymaster/Dean fryers are tested, adjusted and calibrated to sea level conditions before leaving the factory. Adjustments to assure proper operation of pilot may be necessary on installation to meet local conditions, low gas pressure, differences in altitude and variations in gas characteristics. These adjustments correct possible problems caused by rough handling or vibration during shipment, and are to be performed only by qualified service personnel.

These adjustments are the responsibility of the customer and/or the dealer and are not covered by the

Frymaster/Dean warranty.

The inlet pipe at the lower rear of the fryer brings incoming gas to the pilot safety control valve, then to the pilot and main burners. The pilot is located high in the cabinet center, at the base of the frypot.

WARNING

Never use a match or taper to light pilot on this ignition system.

1. Turn gas "ON".

2. Turn electric power "ON" with the appropriate rocker switch or controller/computer.

3. The ignition module will energize the pilot gas supply and the ignitor. The ignitor spark will ignite the pilot gas. The presence of the pilot flame is then proved by a flame sensor, which sends a signal to the main gas supply, opening the valve. The operating thermostat or computer/controller controls the fryer after ignition.

WARNING

In the event of prolonged power failure, the ignition module will shut down and lock out the system. Turn the unit power "OFF" and them back "ON" after power has been re-established.

4. If the pilot flame fails, the ignition module will shut down and lock out the system. To restart, turn the electric power "OFF", wait approximately 5 minutes for the system to recycle itself, then turn the power "ON" again. Repeat Steps 1-3.

4-2



4.2 Boil-Out Procedure

DANGER

Never leave the fryer unattended during the boil-out process. If the boil-out solution boils over, turn the fryer off immediately and let the solution cool for a few minutes before resuming the process. To lessen the chance of boil over, turn the fryer’s gas valve knob to the PILOT position occasionally.

WARNING

Do not drain boil-out solution into a shortening disposal unit, a built-in filtration unit, or a portable filter unit. These units are not intended for this purpose, and will be damaged by the solution.

DANGER

Remove all drops of water from the frypot before filling with cooking oil or shortening. Failure to do so will cause spattering of hot liquid when the oil or shortening is heated to cooking temperature and may cause injury to nearby personnel.

A. Pour cleaning solution into the frypot and add water to the bottom OIL LEVEL line scribed in the back of the frypot.

B. Operating thermostat-equipped fryers: Set dial/temperature controller to 225°F (107ºC), just above that of boiling water.

C. Filtration/Boil-Mode equipped fryers: Turn fryer power switch to "ON". Press the fryer- reset switch (if applicable). Turn the boil-out switch "ON".

CAUTION

If the pilot and main burner go out, the fryer(s) MUST be left completely shut down at least 5 minutes before lighting.

D. The main burner will ignite.

E. When the solution nears boiling point, reset the temperature controller to 200°(93ºC).

F. The burners should shut off just as the water starts to boil.

CAUTION

Do not leave fryer unattended. The boil-out solution may foam and overflow if fryer is

left unattended. Press ON/OFF switch to the "OFF" position (Filtration/Boil-Mode equipped fryers) or reduce temperature (Operating Thermostat equipped fryers) to control this condition.

4-3



4.2 Boil-Out Procedure (cont.)

G. The burners will heat the boil-out solution to a simmer. Simmer the solution for approximately 45 minutes. Wearing protective gloves, scrub the sides of the frypot and the tubes with the L-shaped Teflon brush, being careful not to disturb the temperature sensing probes and the high-limit thermostat.

H. Do not allow the water level to decrease below the bottom OIL LEVEL line in frypot during boil-out operation.

WARNING

Water or boil-out solution

MUST not be allowed to drain into the filter pan or filter system. Irreversible damage will result if water is allowed into the system.

I. After boil out is complete, turn the computer off. Drain the solution from the frypot. Place a metal stockpot of sufficient size to safely hold the entire contents of the frypot under the drain port to collect the water/boil-out solution. Do not allow water or boil-out solution to drain into the filter pan. The filter pump is not designed for water operation, and will be irreparably damaged (see warning statement above).

J. Close the drain, add fresh water (without boil-out solution) and wash all surfaces of the frypot. Drain again.

K. Refill the frypot with fresh water and vinegar to neutralize any residual boil-out solution.

Wash all surfaces of the frypot. Drain completely and wipe down all surfaces of the frypot to completely remove all water.

Computer-equipped fryers: See computer manual for boil-out programming and follow the above procedures for boil-out.

DANGER

Do not go near the area directly over the flue outlet while the fryer is operating.

Always wear oil-proof, insulated gloves when working with the fryer filled with hot oil.

Always drain hot oil into a metal stockpot of sufficient size to safely hold the entire contents of the frypot.

4-4



4.3 Final Preparation

WARNING

NEVER set a complete block of solid shortening on top of heating tubes. To do so will damage the heating tubes and frypot, and void the warranty.

4.3.1 Filling Fryer with Cooking Oil/Shortening

A. When using a liquid shortening (cooking oil), fill the fryer to the bottom OIL LEVEL line scribed into the back of the frypot.

B. When using a solid shortening, cut it into small pieces and pack it below the heat tubes, between the tubes and on top of the tubes, leaving no air spaces around the tubes. Do not disturb or bend the probe sensing bulbs.

C. Press the computer on/off switch to "ON". The burners will initially operate in the MELT

CYCLE mode until the shortening reaches 180°F. It will then automatically switch to normal operation.

D. When the frypot is filled and the shortening is melted, carefully replace the crumb screen over the heat tubes. Wear oil-proof insulated gloves to avoid the potential for burn injury when placing crumb screen in frypot.

For additional computer instructions, see computer manual that came with frying system.

4-5


CHAPTER 5: FILTRATION OPERATION

WARNING

Drawings and photos used in this manual are intended to illustrate operational, cleaning and technical procedures and may not conform to on-site management operational procedures.

5.1 General

Frymaster FPD65 Series gas fryer filter systems come equipped with a filter-leaf assembly, which eliminates the need for filter paper. Filter powder is used to enhance the filtration process.

5.2 Filtration Preparation

On initial installation and before each use, remove all loose parts from the filter, wash the filter pan and all accessories in hot, soapy water and dry thoroughly.

5.2.1 Assembling the Filter

Frymaster FPD65 Series filter systems incorporate a filter-leaf assembly, in which a fine mesh screen is used to filter impurities and debris from the oil. The oil is pumped through the screen and then returned to the frypot.

Assemble the filter pan as follows (see illustration below):

1. Filter pan assembly.

2. Filter-leaf assembly.

3. Crumb screen.

4. Front filter pan cover.

5. Rear filter pan cover.

5

2

4

3

1

5-1



5.2.1 Assembling the Filter (cont.)

Assemble the filter as follows:

1. Remove the filter pan covers.

2. Place the filter leaf assembly in the bottom of the filter pan, ensuring the filter disconnect is properly placed in the filter pan slot. Support the screen assembly by holding the supply pipe during installation.

Filter pan with covers removed.

3. Ensure the filter screen lies flat in the bottom of the pan and the supply connection bracket is properly positioned in the pan slot before proceeding.

The bracket fits into a slot in the pan.

Filter leaf properly positioned in filter pan.

5-2



5.2.1 Assembling the Filter (cont.)

4. Place the crumb tray in filter pan.

5. Replace the pan covers and install the filter pan into the cabinet. Ensure the connections are fully engaged. Ensure the filter pan opening is directly under the drain tubes to avoid splashing hot oil. The fryer is ready for filtering.

Crumb screen placement in filter pan.

The filter pan slides under the fryer (above), connecting with a slip fitting (right). The slip fitting is located between the drain tubes (above, arrow).

5-3



5.2.2 Disassembling/Assembling and Cleaning an Optional Filter Leaf

Follow these steps to clean a leaf-style filter:

4

1

2

1 3

Filter Leaf Disassembly/Assembly

Grasp the seal frame near each corner at the locking tab (1) and pull frame apart The seal frame will separate into two pieces. Separate the top and bottom screens (2 & 3) and remove the grid (4).

Assemble in reverse order.

5-4



Cleaning the Filter Leaf Assembly

Clean the two seal frame pieces, screens and grid using a good quality degreaser and hot water from a spray nozzle. The groove in the seal frame pieces can be cleaned with the edge of a Scotch-Brite or similar cleaning pad.

At each scheduled boil out, disassemble the filter leaf as described in Section 5.7.1 and place in the frypot filled with boil-out solution. Follow the boil-out procedure in Section 4.4.1, including placing the filter leaf in the vinegar solution to neutralize boil-out residue, and clean water to rinse away vinegar residue.

Allow all filter leaf components to air dry or thoroughly dry with paper towels.

5.3 Daily Filtration Operation

WARNING

Use caution and wear proper protective clothing. The oil to be filtered is at or near

350°F (177°C). Ensure all hoses are connected properly and drain handles are in their proper position prior to operating any switches or valves. Failure to do this can result in severe burns.

WARNING

Drawings and photos used in this manual are intended to illustrate operational, cleaning and technical procedures and may not conform to on-site management operational procedures.

5.3.1 General Overview

The filter pump is turned on only after the oil is brought to operating temperature and drained into the prepared filter pan. The filter motor is then engaged and oil is drawn through the filter leaf assembly and pumped back into the frypot. The frypot drain valve remains open during the filtering process. The oil is cycled through the filter leaf assembly for approximately 10 minutes (see computer section for specific instructions). At the end of 10 minutes, the drain valve is closed, allowing the oil to pump back into the frypot. The pump should run for 15-30 seconds after bubbles appear in the frypot to ensure all oil or shortening is pumped from the drain pan and the oil-return lines. The frypot oil level should return to the top OIL LEVEL line. If not, add fresh oil or shortening to obtain the proper level. Remember, the oil is at operating temperature during all filtration procedures.

The filter pump can be activated with a manual On/Off switch located under the fryer control panel if the oil-return, drain-flush or wand/dispose valves fail to activate the pump when opened. Contact an authorized service technician immediately for repair.

Refer to specific store procedures for correct filter operation. Additional information can be found in the computer section of this manual.

5-5



5.3.2 Filtering Tools

Assemble tools to be used for filtering. These are supplied with the filter starter kit included with the fryer/filter system:

• Frypot/Filter Brush– used to clean frypot and filter pan sides and bottom, heating tubes, and to dislodge sediment during filtration or shortening change.

• Clean-Out Rod– used to dislodge heavy debris in the drain tube (when needed).

The following tools are not required, but are recommended:

• Measuring Cup– used to measure filter powder.

• Fine Mesh Skimmer– used to remove large debris.

Note: Prior to proceeding, put on safety goggles, neoprene gloves and heavy vinyl apron.

NOTICE

Follow specific store procedures when filtering the fryer. In the event store procedures are not available, the following instructions can be followed until specific store procedures are obtained.

WARNING

Filter ONLY one frypot at a time. The filter pan is designed to hold the contents of

one frypot ONLY.

5-6



5.4 Operating the Filter

5.4.1 Filter Operation

CAUTION

NEVER operate the filter unit unless cooking oil is at operating temperature [~350°F

(~177°C)].

1. Remove fry baskets from frypot. Prior to filtering, skim any large debris from the oil with the fine mesh skimmer. Use extreme caution, as oil is at or near operating temperature [~350°F (~177°C)]. Use a metal scraper to gently remove debris from frypot walls above shortening level.

2. Pour 12 ounces by volume of filter powder into the vat. Carefully stir the powder into the oil with the fine mesh skimmer.

Prior to filtering, skim any large debris from oil in frypot.

3. Ensure the oil is at operating temperature

(~350°F/177°C). Open the fryer drain valve.

Allow the oil to drain into the filter pan. The computer will display OPEN DRAIN.

Adding filter powder to vat prior to filtering.

Pull red handle to open drain valve and allow hot shortening to drain into filter pan.

5-7



5.4.1 Filter Operation (cont.)

4. When all the oil has drained from the frypot, connect the hose-wand assembly to the disconnect valve in the fryer cabinet. DO

NOT ACTIVATE FILTER PUMP UNTIL

THE HOSE HAS BEEN PROPERLY

CONNECTED. Ensure the hose-disconnect is properly connected before proceeding.

Remove the frypot wire rack prior to rinsing frypot.

5. Place the hose wand into the frypot being filtered and activate the rinse valve by turning

Hose/wand disconnect properly connected to disconnect valve in fryer cabinet (orientation of disconnect may vary according to system). the blue handle to "WAND" (where applicable), or by pressing the manual bypass switch (systems without oil disposal system).

The filter pump will activate and oil will start flowing through the rinse hose.

After the hose wand end is properly positioned in the frypot, activate the filter pump by turning the blue handle to "WAND" (where applicable).

6. Hold the wand inside the frypot at a 45degree angle while the rinse valve is opened.

7. Use the wand to rinse debris from the frypot for approximately 3 minutes. At the end of 3 minutes, the computer display will alternate from OPEN DRAIN to the timed countdown cycle (10 minutes). Turn the blue handle or the manual bypass switch to "OFF", and then close the drain valve (red handle).

Disconnect and drain the hose of all shortening or oil. Hang hose upright to ensure no shortening remains in hose.

Use the wand to rinse debris from the frypot into the filter pan. Maintain a firm grip on the wand handle at all times.

5-8




8. Begin the filtering process by pulling the yellow handle to open the oil-return valve

(this activates the filter pump automatically).

9. Oil will begin to pump from the filter pan into the frypot. Allow the oil to circulate

Begin the filtering process by pulling yellow handle to open oil return valve. Leave the drain valve

(red handle) open during the filtering process. through the frypot for the remainder of the timed countdown (approximately 10 minutes). This process is known as

"polishing".

10. The computer will display FILL at the end of the timed countdown. Replace the frypot grid rack. Close the red drain valve handle to begin refilling the frypot.

Polishing the oil removes suspended particles, which increases the life of the oil.

When the computer displays FILL, close the drain valve to begin refilling the frypot.

5-9




11. After all shortening is pumped back into the frypot, bubbles will form, indicating air in the oil return lines. Allow the shortening to bubble for 15-30 seconds to ensure all shortening is cleared from the return lines.

An audible alarm will sound, indicating that the frypot is full. Push the yellow handle to close the oil return valve and deactivate the filter pump.

12. If the shortening level is low, add fresh

Allow the oil to bubble for 15-30 seconds to ensure evacuation of all oil in the return lines. shortening until the level is at the top OIL

LEVEL line (the shortening is at operating temperature).

13. Do not allow crumbs to accumulate in the crumb tray. The crumb tray MUST be emptied into a fireproof container at the end of frying operations EACH day.

Add fresh shortening until the level is at the top

OIL LEVEL line. DO NOT OVERFILL THE

FRYPOT.

Empty the filter pan crumb tray into a fire-proof container at the end of frying operations each day.

DO NOT ALLOW CRUMBS TO ACCUMULATE IN

TRAY.

5-10




14. OPTIONAL EQUIPMENT: Drain-flushes are included on 5-battery and larger

Frymaster FPD65 Series fryers. After filtering frypot farthest from the filter system for 10 minutes, close the oil return valve to stop the filtering process. Do not refill the frypot. Close the drain valve (red handle) on the frypot being filtered. Ensure all other valves (red and yellow handles) are closed.

Pull the blue handle to open the flush valve

(6-battery systems have two). After the drain line is clear of sediment (approximately 2 minutes), push the blue handle to close flush valve. Open the oil-return valve (yellow handle) to refill the frypot.

15. OPTIONAL EQUIPMENT: Shortening

Disposal: Follow store procedures when

Left drain-flush handle location (arrow) for frypot

#6. disposing of spent shortening. Ensure the

Shortening Disposal System is properly connected and working properly before proceeding. Turn the blue handle on the wand/dispose valve to "DISPOSE" to start the disposal process. Turn the blue handle to

"OFF" when the disposal process for that frypot is complete.

Blue handle in "DISPOSE" position. Turn handle to "OFF" after spent shortening is disposed of.

DANGER

The crumb tray in fryers equipped with a filter system must be emptied into a fireproof container at the end of frying operations each day. Some food particles can spontaneously combust if left soaking in certain shortening material.

WARNING

Do not bang fry baskets or other utensils on the fryer’s joiner strip. The strip is present to seal the joint between the frypots. Banging fry baskets on the strip to dislodge shortening will distort the strip, adversely affecting its fit. It is designed for a tight fit and should only be removed for cleaning.

5-11


CHAPTER 6: PREVENTATIVE MAINTENANCE

6.1 General

DANGER

Never attempt to clean the fryer during the cooking process or when the frypot is filled with hot oil/shortening. If water comes in contact with oil/shortening heated to cooking temperature, it will cause spattering of the oil/shortening, which can result in severe burns to nearby personnel.

Any equipment works better and lasts longer when maintained properly and kept clean. Cooking equipment is no exception. Frymaster FPD65 Series gas fryers should be kept clean during the working day, and thoroughly cleaned at the end of each day. Below are recommendations for daily, weekly and periodic preventative maintenance.

6.1.1 Daily

WARNING

Use a commercial grade cleaner formulated to effectively clean and sanitize foodcontact surfaces. Read the directions and precautionary statements for use.

Particular attention must be paid to the concentration of cleaner and the length of time the cleaner remains on the food-contact surfaces.

A. Remove and wash all removable parts.

B. Clean all exterior surfaces of the cabinet. Do not use cleaners, steel wool, or any other abrasive material on stainless steel.

C. Filter the cooking oil and replace if necessary. The oil should be filtered more frequently when under heavy use.

D. Clean filter pan, as well as, crumb tray as discussed on page 5-9.

6.1.2 Weekly

A. Completely drain the oil from the fryer into a metal stockpot of sufficient size to safely hold the entire contents of the frypot for disposal. Do not use a glass or plastic container.

B. Clean the frypot by following boil-out procedures in Chapter 4.2.

WARNING

Never allow water to boil down and expose the heating tubes. Frypot damage will result.

6-1



6.1.3 Periodic/ Annual

The fryer should be inspected and adjusted periodically by qualified service personnel as part of a regular kitchen maintenance program.

Frymaster/Dean recommends that the fryer be inspected at least annually by a Factory

Authorized Service Technician as follows:

• Inspect fryer cabinet inside and out, front and rear, for excessive oil build-up and/or oil migration. Verify that burners and associated components (i.e. gas valves, pilot assemblies, ignitors, etc.) are in good condition and functioning properly. Inspect all gas connections for leaks and ensure all connections are properly tightened.

• Verify that temperature and high-limit probes are properly connected, tightened and functioning properly.

• Verify all component box components (i.e. computer/controller, relays, transformers, interface boards, etc.) are in good condition and free from oil migration build-up and other debris. Inspect component box wiring and ensure all connections are tight and all wiring is in good condition.

Ensure all safety features (i.e. drain safety switches, reset switches, etc.) are present and functioning properly.

• Verify that frypot is in good condition and free of leaks. Verify that frypot tube diffusers are present and in good condition (i.e. no visible deterioration or damage).

• Verify that all wiring and connections are tight and in good condition.

Built-in Filtration:

• Inspect all oil-return and drain lines for leaks and verify that all connections are tight.

• Inspect the filter pan for leaks and cleanliness. If there is a large accumulation of crumbs in the crumb basket, advise the owner/operator that the crumb basket should be emptied into a fireproof container and cleaned daily.

• Verify that all O-rings and seals (including those on quick-disconnect fittings) are present and in good condition. Replace O-rings and seals if worn or damaged.

6-2



6.1.3 Periodic/ Annual (cont.)

• Check filtration system integrity as follows:

− With the filter pan empty, place each oil return handle, one at a time, in the "ON" position.

Verify that the pump activates and that bubbles appear in the cooking oil/shortening of the associated frypot.

− Close all oil return valves (i.e., place all oil return handles in the "OFF" position). Verify proper functioning of each oil return valve by activating the filter pump using the lever on one of the oil return handle microswitches. No air bubbles should be visible in any frypot.

− Verify that the filter pan is properly prepared for filtering, then drain a frypot of oil heated to

350°F (177°C) into the filter pan and close the frypot drain valve. Place the oil return handle in the "ON" position. Allow all cooking oil/shortening to return to the frypot (indicated by bubbles in the cooking oil/shortening. Return the oil return handle to the "OFF" position. The frypot should refill in no more than 2 minutes and 30 seconds.

To ensure good fryer health and a safe environment, the fryer should be checked and adjusted periodically by qualified service personnel as part of a regular kitchen maintenance program.

6.1.4 Stainless Steel Care

DANGER

DO NOT let water splash into the tank of hot oil. It will splatter and can cause severe burns.

All stainless steel fryer cabinet parts should be wiped regularly with hot, soapy water during the day, and with a liquid cleanser designed for stainless steel at the end of each day.

A. Do not use steel wool, abrasive cloths, cleansers or powders.

B. Do not use a metal knife, spatula or any other metal tool to scrape stainless steel! Scratches are almost impossible to remove.

C. If it is necessary to scrape the stainless steel to remove any encrusted materials, soak the area first to soften the deposit, then use a wood or nylon scraper only.

6-3

7.1 General


CHAPTER 7: TROUBLESHOOTING

DANGER

Hot cooking oil/shortening will cause severe burns. Never attempt to move this appliance when filled with hot cooking oil/shortening or to transfer hot cooking oil/shortening 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.

The problems and possible solutions covered are those most commonly encountered. To troubleshoot, perform the test set-up at the beginning of each condition. Follow each step in sequence.

7.2 Pilot Burner Malfunction

A. Pilot will not ignite; no evidence of gas at pilot burner.

1. Check that gas valve is open and gas is present at the gas valve.

2. Check pilot burner orifice for dirt or lint.

3. Authorized Service Agent Only: Remove pilot burner gas-supply line and check for contamination; blow out if necessary, then reinstall.

B. Pilot burner ignites but will not remain lit when gas valve manual knob is released.

1. Check that thermopile lead is properly connected at the terminal block on the gas valve.

2. Authorized Service Agent Only: Pilot flame may be too high or too low. Adjust pilot flame adjustment screw so that pilot flame extends about 3/4-inch (19-mm) above the top of the pilot burner.

7-1



7.2 Pilot Burner Malfunction (cont.)

3. Check all connections for cleanliness and security.

C. Pilot flame of proper size, but is unstable. Flame wavers and does not envelop the thermopile completely at all times.

1. Check for drafts that might be caused by air conditioning equipment or make-up air apparatus. Turn air-moving equipment off and recheck the pilot.

7.3 Main Burner Malfunctions

A. Main burner will not come "ON"; gas not detected at main burner.

1. Check that the gas valve is open.

2. Check that the pilot is ignited and is operating properly.

3. Authorized Service Agent Only: Check the high-limit switch for continuity.

4. Authorized Service Agent Only: Check the combination gas valve and replace if defective.

B. Main burner flames are small and appear lazy; shortening does not come up to temperature quickly.

1. Authorized Service Agent Only: Check gas pressure at the pressure tap of the gas valve.

Use dial type or standard water-type U-gauge manometer. With burner in operation, the pressure should be 4" W.C. (10 mbar) for natural gas, and 11" W.C. (27.5 mbar) for propane. If not, remove the pressure regulator adjustment cover. Use screwdriver to turn the adjusting screw for proper pressure. Replace cover, re-check pressure and reinstall pressure tap plug.

C. Signs of excessive temperature; shortening scorches and quickly becomes discolored.

1. Check operating thermostat. May be out of adjustment or calibration. Recalibrate if necessary.

2. Check gas pressure as outlined above.

3. Shortening used is of inferior quality and/or shortening has been used too long. Replace shortening.

4. Ensure frypot is clean when refilling with new shortening.

7-2



7.3 Main Burner Malfunctions (cont.)

D. Fryer will not reach the temperature setting and/or runs erratically.

1. Incorrect location of sensor probe or defective temperature sensor.

2. Loose wiring/wire connection

E. Fryer shortening temperature cannot be controlled; fryer runs at high-limit temperature.

1. Defective temperature probe; Call Authorized Service Agent.

7-3



7.4 Wiring Diagram, Main

GND

BLK

WHT

FUSE

FUSE

WHT

BLU

WHT

BLU

7-4

RED

YEL

RED



7.5 Wiring Diagram, Filter

7-5


CHAPTER 8: PARTS LIST

8.1 Cabinetry and Related Components

Typical Cabinetry Components

(FPD665 Shown) 22

23

21

20

25

15

24

19

18

17

16

14

2

1

3

10

11

12

13

7

6

4

8

5

9

8-1



8.1 Cabinetry and Related Components (cont.)

ITEM PART # COMPONENT

7

8

9

10

11

12

13

4

5

6

*

1

2

3

14

15

16

17

18

19

20

810-0357

810-0356

823-3248

202-1182

201-1182

200-1463

200-2493

200-1198

823-3352

200-1493

200-1611

200-4241

200-2308

200-1393

200-1471

202-1299

201-4775

202-4775

201-4237

202-4237

201-1299

Caster, 5" Swivel – With Brake

Caster, 5" Swivel – Without Brake

Support, Caster- Channel Base

Gusset, Side Panel- Left

Gusset, Side Panel- Right

Channel, Base- Front & Rear- 2-Battery (FPD565 & FPD665)

Channel, Base- Front & Rear- 1-Battery (FPD565 Only)

Channel, Base- UFF Filter

Support, Caster- UFF Base

Frame, Base Lower Plate- UFF

Base, Upper- UFF

Plate, Motor Support- Offset

Post, Door- UFF Cabinet

Channel, Lower Joiner

Duct, Door Access

Panel, Side- Painted- Right

Panel, Inner- Left

Panel, Inner- Right

Panel, Inner UFF- Left

Panel, Inner UFF- Right

Panel, Side- Painted- Left

22

*

23

24

25

* Not Illustrated

200-3696

200-3694

200-1425

200-4238

210-3700

Back, Upper Structural (FPD665)

Back, Upper Structural (FPD565)

Back, Lower Structural- Right & Left Cabinet

Back, Lower Structural- Middle UFF Cabinet

Hanger, Basket- 2-Battery

8-2



8.2 Doors, Topcaps and Related Components

1

FPD665 Shown

3

2

13

4 5

6

COMPONENT

12 11

10

9

8

7

ITEM PART #

3 824-0951 Wireway, Control Panel (Component Box: See Section 8.4 For

Electronic Components)

5 200-1185 Inner

6 210-1424 Outer

7 810-2105 Handle, Door- Chrome

8

9

10

*

*

11

12

13

*

* Not Illustrated

809-0918

809-0191

810-0066

810-1105

200-3663

809-0266

810-0179

200-1675

809-0413

Screw, #10-24 x ½" (Use With 810-2105)

Washer, ¼" Lock (Use With 810-2105)

Magnet, Door Catch- All Doors Except Filter

Magnet, Door Catch- Filter Cabinet Doors

Plate, Door Magnet (Use Where Magnet Contacts Stainless Steel)

Screw, #10 x ½"

Plug, Access (Handle Screws)

Hinge, Lower Bracket- Door

Spacer, Nylon- Lower Hinge/Door Pin

8-3



8.3 Frypots, Burners and Related Components

28

30

29

1

2

25

26

24

3

5

27

23 22 18

19

21

17 16

20

15

14

6

4 8

13 12 11

10

7

9

8-4



8.3 Frypots, Burners and Related Components (cont.)

ITEM PART # COMPONENT

1

2

823-3948

210-5170

Frypot- S/S- 65 Series

Diffuser, Burner Tube

9

10

11

12

13

*

*

*

6

7

21

*

*

22

23

*

24

*

15

*

16

17

18

19

20

25

*

26

*

27

28

*

*

29

30

* Not Illustrated

200-2738

200-2746

200-1615

809-0822

810-2138

813-0642

813-0705

813-0643

810-2050

810-2324

807-3628

807-3552

813-0174

813-0635

813-0066

813-0743

813-0165

813-0670

813-0585

813-0737

810-2043

809-0805

200-1450

807-1553

807-1311

Bracket, Burner Mounting

Shield, Burner Heat

Bracket, Manifold Mounting

Bolt, ¼-20 x ½" Hex Head

Valve, Trailing Pilot

Tee, 1/8" NPT

Plug, Brass- 1/8" Square Head

Nipple, 1/8" NPT x Close BM

Orifice, Natural- #44 (2.18 mm)

Orifice, LP- #53 (1.40 mm)

Valve, Gas- LP-24V, Honeywell

Valve, Gas- Natural-24V, Honeywell

Union- ¾" NPT BM

Nipple, ¾ NPT x 2-½" BM

Elbow- ¾" NPT 90° BM

Nipple, ¾ NPT x 3-½" BM

Elbow, Street- ½" NPT 90° BM

Nipple, ½ NPT x 19" BM (Measure To Confirm Length)

Nipple, ½ NPT x 20-½" BM (Measure To Confirm Length)

Nipple, ½ NPT x 21" BM (Measure To Confirm Length)

Clamp, Pipe- ½"

Bolt, Pipe Clamp- ¼-20 x ½" Hex

Bracket, Gas-Supply Clamp Support (UFF-Equipped Systems)

Burner, Pilot- LP- Electronic Ignition

Burner, Pilot- Natural- Electronic Ignition

810-0703

810-0705

810-2155

810-2032

Gas Line, Main Pilot Supply- ¼ x 17-½"

Gas Line, Main Pilot Supply- ¼ x 23"

Burner, Trailing Pilot- LP

Burner, Trailing Pilot- Natural

812-1544 Gas Line, Trailing Pilot Supply- ¼ x 12" (Not For Main Pilot)

106-2634SP Flue Assembly, Complete

200-4087

200-4088

Front, Flue Box

Rear, Flue Box

810-2524 Grid, Frypot- 65 Series

106-2897SP Cover, Frypot- 65 Series

8-5



8.4 Component Box Components

3

15

17

4

1

14

16

13

12

11

10

9

8

2

5

6

7

11

12

*

13

15

16

CM4-S

18

ITEM

1

2

PART #

823-3242

210-1364

COMPONENT

Control Box (Inside Non-Filter Fryer Cabinets)

Plate, Face (For Item #1)

3 200-1322 Bracket, Spark Module

4 200-1326 Module

7

8

9

10

5

*

6

807-3563

807-1315

826-2434

826-2425

807-0833

807-0855

807-0800

807-1321

Module, Ignition (Spark)

Cable, Ignition Module

Interface Board, Electronic Ignition

Interface Board, Standing Pilot

Relay, 12VDC 5A 1PDT (Latching)

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

Transformer, 120VAC 50/60 Hz -24V 50VA

Fuse Holder, Buss

807-3580

807-3577

807-3538

807-3680

200-2052

807-3611

Switch, Rocker- Manual Filter Power

Breaker, Circuit- 7-Amp (115VAC Circuits)

Breaker, Circuit- 5-Amp (230VAC Circuits)

High-Limit Thermostat- Manual Reset 450° F (Non-CE Only)

Bracket, Sound Device

Relay, Filter- 24VAC Coil 24A

18 806-8305

106-3028

Computer, CM4-S- With Bezel Generic (Segmented Programming)

Computer, CM4-S- With Bezel Church’s Only (Segmented. Prog.)

* 823-3433 Computer

* Not Illustrated

8-6



8.5 Filter Pan and Related Components

11

10

12

14 13

6

5

4

7

8

9

1

2

3

ITEM

5

6

*

2

3

4

*

9

10

11

*

*

12

13

* Not Illustrated

PART #

810-2141

809-0823

810-2350

810-2583

810-2582

803-0002

813-0679

823-3178

210-1592

810-2105

809-0918

809-0191

200-2713

210-1180

COMPONENT

Caster, Filter Pan- 2"

Nut, Nylock- ¼-20

Leaf, Filter- 14-½ x 22-½"

Fitting, Bottom- Filter Leaf

Fitting, Top- Filter Leaf

Powder, Filter- Box (Filter Magic- 100 1-Cup Applications)

Plug, Suction- 1/8" S/S Square Head

Cover, Filter Pan- Front

Cover, Filter Pan- Rear

Handle, Pan Cover- Chrome

Screw, #10-24 x ½" (Use With 810-2105)

Washer, ¼" Lock (Use With 810-2105)

Bracket, Slide Rail

Insert, Slide Rail Bracket

8-7



8.6 Oil-Drain Components

20

19

22

18

17

16

15 8

21

23

5

6

4

2

3

Typical Drain Components

(FPD665 Shown)

1

14

9

7

10 11 12 13

8-8



8.6 Oil-Drain Components (cont.)

7

8

9

10

11

12

13

14

ITEM

1

*

2

3

4

5

6

15

16

17

18

*

*

PART #

823-4189

823-3441

813-0829

809-0884

816-0544

200-1840

813-0749

813-0165

810-1069

810-1057

810-1668

813-0062

813-0096

813-0686

813-0784

106-1401

200-1617

210-2029

200-1940

823-3440

809-0885

COMPONENT

Pipe, Drain- Right- D665 (With Oil Disposal System)

Pipe, Drain- Right- D565 (No Oil-Disposal System)

Elbow, Drain Pipe- 75°

Nut, Slip Joint- 1-½"

O-ring (Slip-Joint Nut)

Drain Manifold Tube

Tee, 1-½" NPT With Handle

Elbow, Street- ½ x ½" 90°

Flex Line, 5/8" x 29-½ " (Measure To Confirm Length)

Flex Line, 5/8 x 13" (Measure To Confirm Length)

Adapter, 5/8" O.D. x ½"- Male (Use With 810-1057 and 810-1069)

Elbow, ½" NPT BM 90°

Nipple, ½ x 6" NPT BM

Bell Reducer, 1-½ x ½" NPT

Drain Pipe, Left Side

Drain Valve Components

Bracket, Microswitch (Optional On Some Units)

Washer, Drain Valve (Use Without Microswitch)

Bracket, Activator- Microswitch

Handle (Actuator), Drain Valve

Handle, Push/Pull- Drain (With Cap)

Washer, 3/8 x 1 x .083"

* 816-0547 Vinyl-Red

19 807-2104 Microswitch (Optional On Some Units)

20 809-0842 Nut, Nylock- #4-40 (Microswitch To Bracket)

Drain Valve, 1-½" Full Port (With Washers & Nut) 23

* Not Illustrated

810-2127

8-9



8.7 Oil-Return Components

10

2

6

5

17 16

2

4

2

10

7

Rinse Hose Plumbing

(Optional)

9

8

3

2

12

13

14

Oil Disposal Plumbing

(Optional)

1

10

15

2

Typical Oil-Return Components

(FPD665 Shown)

ITEM

1

2

* Not Illustrated

PART #

813-0156

813-0022

813-0087

813-0298

813-0265

813-0460

813-0247

813-0251

813-0646

813-0742

813-0674

813-0672

813-0673

813-0698

813-0515

813-0418

813-0670

11

COMPONENT

Plug, Pipe- Hex Head Extruded

Nipple, Pipe (Measure To Confirm Length Prior To Replacing;

Choose From Nipple Lengths Below)

Nipple, ½" x Close NPT BM

Nipple, ½ x 1-½" NPT BM








Nipple, ½ x 7-¼" NPT BM







8-10

*

11

12

13

14

15

*

*

*

*

9

10

*

*

*



8.7 Oil-Return Components (cont.)

ITEM PART #

3

4

5

813-0173

813-0003

813-0165

COMPONENT

Union, ½" NPT BM

Tee, ½" NPT BM

Elbow, Street ½" NPT BM 90°

6

7

8

813-0051

813-0062

810-1003

Coupling, ½" NPT BM

Elbow, ½" NPT BM 90°

Valve, Ball- Three-Way ½" 180°

210-4239

816-0549

Bracket, Wand/Disposal Handle

Cap, Handle- Blue (Cut Length To Fit)

106-1837SP Disconnect Assembly, With Collar

810-0278 Valve, Ball- Oil-Return ½"

823-3187

816-0548

823-4174

Handle, Oil-Return Valve

Cap, Oil-Return Handle- Yellow

Handle Assembly (Actuator)- Oil-Return Valve

809-0885

813-0463

810-1056

823-3996

810-0487

810-1669

810-0278

816-0549

Washer, Actuator- Ball Valve- 3/8 x 1 x 0.083"

Plug, Counter-Sink Hex ½"

Oil Disposal Components

Flexline, Oil Disposal- 5/8 x 52-½"

Nipple Assembly, Oil Disposal

Disconnect, Male- Oil Disposal

Adapter, Female- 5/8 x ½"

Handle, Oil-Return Flush Valve

Cap, Flush Valve Handle- Blue

17

* Not Illustrated

810-2100 Motor, Filter Pump- 120/230VAC 1/3 HP

8.8 Suction Tube, Oil-Return Components

1

8

3

2 7

6

4

5

8-11



8.8 Suction Tube, Oil-Return Components (cont.)

ITEM

1

*

2

3

4

5

6

7

8

* Not Illustrated

PART #

810-0697

826-1392

813-0608

823-3188

813-0062

813-0093

813-0173

813-0165

813-0022

813-0156

813-0003

COMPONENT

Disconnect, Male- Suction Tube

O-ring, Suction Tube Connection (Qty: 5)

Coupling, Full- ½" NPT BM

Suction Manifold Assembly

Elbow, ½" x 90° NPT BM

Nipple, ½ NPT x 4" NPT BM

Union, ½" NPT BM

Elbow, Street- ½" x 90° NPT BM

Oil Suction Start Fitting

Nipple- ½" NPT x Close BM

Plug, ½" NPT BM Hex Head

Tee, ½" NPT BM

8-12

THIS PAGE INTENTIONALLY LEFT BLANK

Frymaster, 8700 Line Avenue, Shreveport, Louisiana 71106

TEL 1-318-865-1711

PRINTED IN THE UNITED STATES

FAX (Parts) 1-318-688-2200 FAX (Tech Support) 1-318-219-7135

SERVICE HOTLINE

1-800-551-8633

819-6039

SEPT 2008

No results