Installation, Operation, and Maintenance Manual |
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For Gas Fryers |
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Covering Models |
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45C+, 35C+ |
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Pitco Frialator, Inc., |
P.O.Box501,JctI-89&I-93Concord,NH03302-0501•509Route3A,Bow,NH03304 |
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(800)258-3708•(603)225-6684•FAX(603)225-8497 |
L20-072 Rev 5 |
(11/03) |
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ENGLISH
FRANCAIS
Pitco Frialator #L20-072 Rev 5 (11/03)
NOTICES
There are three different types of notices that you should be familiar with, a NOTICE, CAUTION, and WARNING. A NOTICE is a special note used to call attention to a particularly important point. CAUTION is used to point out a procedure or operation which may cause equipment damage. The WARNING notice is the most important of the three because it warns of an operation that may cause personal injury. Please familiarize yourself with your new cooker before operating it and heed the notices throughout this manual. The WARNINGS are listed below and on the following page for your review prior to operating the unit.
FOR YOUR SAFETY
DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.
WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment.
ENGLISH
TO THE PURCHASER
POST IN A PROMINENT LOCATION INSTRUCTIONS TO BE FOLLOWED IN THE EVENT THAT AN OPERATOR SMELLS GAS. OBTAIN THIS INFORMATION FROM YOUR LOCAL GAS SUPPLIER.
THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE
SAFETY |
SAFETY |
SAFETY |
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SAFETY |
WARNING 
The cooker must be electrically grounded in accordance with local codes. If local codes do not apply, follow the requirements of National Code ANSI/NFPA 70-1990.
WARNING 
This cooker is equipped with a three prong safety plug. This safety plug protects operators from electrical shock in the event of an equipment malfunction. DO NOT remove the grounding (third) prong from this plug.
WARNING 
DO NOT use an open flame to check for gas leaks!
WARNING 
A cooker that is equipped with casters and a flexible power cord must be connected to the gas supply with a Quick-Disconnect device. This quick disconnect must comply with ANSI Z24.41-1989. A restraining cable must be installed to limit the movement of the cooker.
WARNING 
There is an open gas flame inside the cooker. The unit may get hot enough to set nearby materials on fire. Keep the area around the cooker free from combustible materials.
WARNING 
Ensure that the cooker can get enough air to keep the flame burning correctly. If the flame is starved for air it can give off dangerous carbon monoxide. Carbon Monoxide is a clear odorless gas that can cause suffocation and death.
WARNING 
Be sure the burner tubes are COMPLETELY covered with water before lighting the pilot or main burners. If the tubes are exposed, the cooker may overheat, causing damage to the kettle, creating a fire hazard, and voiding the warranty.
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WARNING 
Carbon monoxide can build up if the flue is blocked. Blocking the flue will also cause the cooker to overheat. Ensure that minimum clearances specified in the installation instructions are maintained. DO NOT obstruct the flow of combustion/ventilation or air opening around the Noodle Cooker. Adequate clearance around the cooker is necessary for servicing and proper burner operation. Ensure that you meet the minimum clearances specified in the installation instructions.
WARNING 
The power supply must be disconnected before servicing or cleaning the appliance.
WARNING 
For gas cookers, DO NOT supply the cooker with a gas that is not listed on the data plate. If you need to convert the cooker to another type of fuel, contact your dealer.
WARNING 
For gas cookers, WAIT five (5) minutes before attempting to relight the pilot. This allows time for any gas remaining in the cooker to dissipate.
THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE
ENGLISH
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Table of Contents
Section |
Title |
Page |
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Table of Contents ............................................................................................................................................ |
i |
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List of Tables and Figures ................................................................................................................................... |
ii |
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Chapter 1: General Information and Installation ..................................................................................... |
1-1 |
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1.1 |
WHICH FRYER DO I HAVE? .................................................................................................. |
1-1 |
1.2 |
CHECKING YOUR NEW FRYER............................................................................................ |
1-1 |
1.2.1 |
Check Your Order ................................................................................................................ |
1-2 |
1.3 |
ASSEMBLY AND LEVELING ................................................................................................. |
1-2 |
1.3.1 |
Leg/Caster Installation and Adjustment ............................................................................... |
1-2 |
1.3.2 |
Assembling Multi Fryer Systems ......................................................................................... |
1-3 |
1.4 |
INSTALLATION ........................................................................................................................ |
1-3 |
1.4.1 |
Installation Clearances.......................................................................................................... |
1-3 |
1.4.2 |
Gas Connection .................................................................................................................... |
1-3 |
1.4.2.1 |
Fuel Types ..................................................................................................................... |
1-4 |
1.4.2.2 |
Gas Line Connection ..................................................................................................... |
1-4 |
1.4.2.3 |
Quick Disconnect Gas Connection ................................................................................ |
1-4 |
1.4.2.4 |
Fuel Supply Line Leak and Pressure Testing ................................................................ |
1-5 |
1.4.3 |
Ventilation and Fire Safety Systems .................................................................................... |
1-5 |
1.5 |
INITIAL ADJUSTMENTS......................................................................................................... |
1-5 |
1.5.1 |
Visual Checks ....................................................................................................................... |
1-6 |
1.5.2 |
Burner Ignition Systems ....................................................................................................... |
1-6 |
1.5.2.1 |
Pilot Flame Adjustment ................................................................................................. |
1-7 |
1.5.3 |
Main Burner System ............................................................................................................. |
1-8 |
1.5.3.1 |
Gas Line Requirements.................................................................................................. |
1-8 |
1.5.3.2 |
Burner Adjustment ........................................................................................................ |
1-8 |
1.5.4 |
Initial Cleaning ..................................................................................................................... |
1-9 |
1.5.5 |
Thermostat Calibration Check ............................................................................................ |
1-10 |
1.5.6 |
Thermostat Calibration ....................................................................................................... |
1-11 |
Chapter 2: |
Operating Instructions ............................................................................................................. |
2-1 |
2.1 |
FILLING THE FRYER ............................................................................................................... |
2-1 |
2.1.1 |
Filling the Fryer With Liquid Shortening ............................................................................. |
2-1 |
2.1.2 |
Filling the Fryer With Solid Shortening ............................................................................... |
2-1 |
2.2 |
OPERATING INSTRUCTIONS ................................................................................................ |
2-2 |
2.2.1 |
Fryer Start-Up ....................................................................................................................... |
2-2 |
2.2.2 |
Melting Solid Shortening...................................................................................................... |
2-2 |
2.2.3 |
Fryer Shutdown .................................................................................................................... |
2-3 |
2.3 |
DAILY CLEANING ................................................................................................................... |
2-3 |
Chapter 3: Owner Maintenance and Adjustments ................................................................................... |
3-1 |
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3.1 |
WEEKLY FRYER CLEANING (BOIL OUT) .......................................................................... |
3-1 |
3.2 |
FLUE INSPECTION .................................................................................................................. |
3-1 |
3.3 |
TROUBLESHOOTING .............................................................................................................. |
3-2 |
ENGLISH
i
List of Tables and Figures
Table |
Title |
Page |
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1-1 |
Fryer Model Information ........................................................................................... |
1-1 |
1-2 |
Ventilation and Fire Safety References ..................................................................... |
1-7 |
Figure |
Title |
Page |
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1-1 |
Pilot Assembly, Flame Adjustment ........................................................................... |
1-8 |
1-2 |
Gas Valve Showing Location of Pressure Regulator and Pilot Adjusters ................. |
1-9 |
ii
Chapter 1: General Information and Installation
Congratulations on the purchase of your new Pitco Frialator universal fryer. This unit will give you many years of reliable service if you follow the simple operation and maintenance procedures in this manual. Contained in this manual are the general installation, operation, and maintenance procedures for the universal fryer Models 45C+, 35C+ and 40C+.
1.1WHICH FRYER DO I HAVE?
There are two models of this gas fryer available. Each fryer has its own model number. To find out which model you have, look inside the door at the equipment identification plate. This plate has a lot of useful information, but to identify which fryer you have, look at the model number block. The model number identifies which fryer you have. A brief description of each model is provided inTable 1-1.
Table 1-1 Fryer Model Information
Model |
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Number |
Description |
Features |
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Frying Area: 14" x 14" |
45C+ |
This fryer can cook up to 85 lbs. of potatoes per hour. |
Oil Capacity: 42 lbs. |
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BTU Input: 122,000 |
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Frying Area: 14" x 14" |
35C+ |
This fryer can cook up to 63 lbs. of potatoes per hour. |
Oil Capacity: 35 lbs. |
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BTU Input: 90,000 |
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1.2CHECKING YOUR NEW FRYER
Your new fryer has been carefully packed into one crate. Every effort has been made to ensure that your fryer is delivered to you in perfect condition. As you unpack your new fryer, inspect each of the pieces for damage. If something is damaged, DO NOT sign the bill of lading. Contact the shipper immediately, the shipper is only responsible for 15 days after delivery. Check the packing list enclosed with your fryer to ensure that you have received all of the parts to the fryer. If you are missing any parts, contact the dealer from whom the fryer was purchased. As you unpack the fryer and it's accessories
be careful to keep the weight of the fryer evenly distributed.
X X
ENGLISH
Locate your Pitco Frialator warranty and fill in the serial number of the fryer and the date received. You will find the serial number on the plate inside the door. Put your warranty card in a safe place for future reference. DO NOT return the card to Pitco Frialator.
1.2.1Check Your Order
The crate containing the fryer unit will also contain the following:
(2)Pitco Cleaner Sample
(1)Drain Clean Out Rod
1.3ASSEMBLY AND LEVELING
When you receive your fryer, it is completely assembled with the possible exception of the legs (or casters) and the heat shield. In some cases, if you have purchased a multi-fryer unit, you may need to assemble the system.
1.3.1Leg/Caster Installation and Adjustment
Installing the legs and leveling the fryer is done with a 7/16" wrench, socket, and a large pair of water pump pliers. The legs/casters must be installed to provide the necessary height to meet sanitation requirements and assure adequate air supply to the burner. Attach the legs by performing the following procedure.
a. Lay the fryer on its side being careful not to damage the flue by pulling on it. Protect the outside of the fryer with cardboard or a drop cloth when laying it down.
b.Attach each leg/caster with the hex head cap screws supplied with the fryer. Each leg/caster requires four 1/4-20 x 5/8" cap screws.
Adjust Here
c.Mount the screws from the inside of the fryer with the nut on the outside. The nuts have lock washers attached to them, therefore it is not necessary to use lock washers.
d.When all four legs/casters are mounted, stand the unit up being careful not to put too much weight on any one leg/ caster. Adjust the height and level the fryer by adjusting the leveling devices on the leg/caster with the water pump pliers.
e.On units with casters, move the fryer to the desired location and lock the wheels using the locking devices on the sides of the casters.
1-2
Adjust |
Lock |
Here |
Un Lock
1.3.2Assembling Multi Fryer Systems
If you purchased a multi-fryer unit, it could be shipped in more than one piece. To assemble the unit follow the instructions below.
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a. Unpack the units and move them close together. Remove the front panels and both heat |
ENGLISH |
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shields from the fryers. |
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b. There are five joining strips to be attached to the units to make them into one system. These |
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strips are attached in the rear, front, upper front, and the forward and rear caster mount. Use |
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the screws supplied with your system to attach the strips. Secure them tightly to each unit. |
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c. Replace the heat shield and front panels to complete the system assembly. |
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1.4 |
INSTALLATION |
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Although it is possible for you to install and set up your new fryer, it is STRONGLY recommended that you have it done by qualified professionals. The professionals that install your new fryer will know the local building codes and ensure that your installation is safe.
WARNING
The fryer must be properly restrained to prevent movement or tipping. This restraint must prevent the fryer from movements that would splash hot liquids on personnel. This restraint may be any means (alcove installation, adequate ties, or battery installation).
1.4.1InstallationClearances
The fryer needs clearance around it for proper operation. Adequate clearances allow for servicing and proper burner operation. The clearances shown below are for cooker installation in combustible and non-combustibleconstruction.
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Combustible |
Non-Combustible |
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Construction |
Construction |
Back |
6" |
0" |
Sides |
6" |
0" |
Floor - Combustible |
6" |
6" |
1.4.2Gas Connection
Your fryer will give you peak performance when the gas supply line is of sufficient size to provide the correct gas flow. The gas line must be installed to meet the local building codes or National Fuel Gas
1-3
Code (NFPA 54-Latest Edition) and ANSI Z223.1-Latest Edition Latest Edition. In Canada, install the fryer in accordance with CAN/CGA-B149.1 or .2 and local codes. Gas line sizing requirements can be determined by your local gas company by referring to National Fuel Gas Code, Appendix C, Table C-4 (natural gas) and Table C-16 (propane). The gas line needs to be large enough to supply the necessary amount of fuel to all appliances without losing pressure to any appliance. Other factors that are used to determine the piping requirements are BTU requirements of the appliances being connected and the length of pipe between the meter (main shut off) and the appliances.
WARNING
NEVER supply the fryer with a gas that is not indicated on the data plate. Using the incorrect gas type will cause improper operation. If you need to convert the fryer to another type of fuel, contact your dealer.
1.4.2.1 Fuel Types - Each fryer is equipped to work with one type of fuel. The type of fuel with which the appliance is intended to operate is stamped on the data plate attached to the inside of the door.
WARNING
DO NOT use an open flame to check for gas leaks!
1.4.2.2 Gas Line Connection - Connect the fryer to the gas supply line with a connector that complies with the Standard for Connectors for Movable Gas Appliances (ANSI Z21.69-Latest Edition). If you are installing a fryer with casters use a quick disconnect refer to the Quick Disconnect installationinstruction,1.4.2.3. Connectthegaslinetothefryerusingapipejointsealantthatisresistant to liquefied petroleum. If the fryer was disconnected during the fuel line testing, use a solution of soap and water to leak test the new connection.
NOTICE
NEVER use an adaptor to make a smaller gas supply line fit the cooker connection. This may not allow proper gas flow for optimum burner operation, resulting in poor cooker performance.
1.4.2.3 Quick Disconnect Gas Connection - Gas fryers equipped with casters must be installed with connectors that comply with the Standard for Connectors for Movable Gas Appliances, ANSI Z21.69-Latest Edition, and Addenda Z21.69A-Latest Edition. This connection should include a quick disconnect device that complies with the Standard for Quick Disconnect Devices for Use With Gas Fuel , ANSI Z21.41-Latest Edition. When installing a quick disconnect you must also install a means for limiting the movement of the fryer. This device will prevent the gas line or the quick disconnect from being strained. The restraining device should be attached to the cooker on the back panel as shown in the illustration. The quick disconnect, hose, and restraining device can be obtained from your dealer.
1-4
1.4.2.4 Fuel Supply Line Leak and Pressure Testing- The fuel supply system must be tested before the fryer is used. If the fuel line is going to be tested at a pressure greater than (>)1/2 PSIG (3.45 kPa), make sure that the fryer is disconnected from the fuel line. If the fuel line is to be tested at a pressure equal to or less than (<) 1/2 PSIG (3.45 kPa), the fryer can be connected but the unit's gas valve must be shut. Test all gas line connections for leaks with a solution of soap and water when pressure is applied.
1.4.3Ventilation and Fire Safety Systems
Your new fryer must have proper ventilation to function safely and properly. Exhaust gas temperatures can reach as high as 1200°F. Therefore, it is very important to install a fire safety system. Your ventilation system should be designed to allow for easy cleaning. Frequent cleaning of the ventilation system and the fryer will reduce the chances of fire. Table 1-2 provides a list of reference documents that provide guidance on ventilation and fire safety systems. This table is not necessarily complete. AdditionalinformationcanbeobtainedfromtheAmericanGasAssociation,8501EastPleasantValley Road, Cleveland, OH 44131.
Excessive ventilation causes drafts, which will interfere with the proper operation of the pilot and the burner. Leave at least 18 inches of open space between the fryer's flue vent opening and the intake of the exhaust hood.
CAUTION
Ensure that your ventilation system does not cause a down draft at the fryer's flue opening. Down drafts will not allow the fryer to exhaust properly and will cause overheating which may cause permanent damage. Damage caused by down drafts will not be covered under equipment warranty. NEVER allow anything to obstruct the flow of combustibles or ventilation exiting from the fryer flue. DO NOT put anything on top of the flue area.
NOTICE
NEVER connect the blower directly to the flue openings. The direct flow of air will cause poor temperature recovery, poor ignition, inefficient operation of the fryer, and could extinguish the pilot.
1.5INITIAL ADJUSTMENTS
After your fryer has been installed as described in section 1.4, it needs to be adjusted to ensure that it will perform as designed. These adjustments must be performed by a qualified person. To perform these adjustment the following tools will be needed:
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Manometer (low pressure gauge) |
• Digital Thermometer (Temperature probe) |
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DC Millivolt Meter |
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ENGLISH
1-5
1.5.1Visual Checks
After the fryer is in its permanent location, lock the casters and check for levelness. Any additional leveling that is necessary can be performed as described in section 1.3.
1.5.2Burner Ignition Systems
CAUTION
Before going any further, fill the fryer with WATER. Water is used for the installation adjustments because the temperature will never exceed 212°F (100°C) thereby allowing plenty of adjustment time. Never let the water level go below the MIN LEVEL mark on the rear of the tank.
WARNING
There is an open flame inside the fryer. The unit may get hot enough to set near by materials on fire. Keep the area around the fryer free from combustibles.
Table 1-2. Ventilation and Fire Safety References
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Underwriters Laboratory |
National Fuel Gas Code |
Topic |
Document |
Document |
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Grease Extractor |
ANSI/UL 710-Latest Edition |
ANSI/NFPA 96-Latest Edition |
Ventilation Hood |
ANSI/UL 705-Latest Edition |
ANSI/NFPA 96-Latest Edition |
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Type of Fire Extinguishers |
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and Detection Equipment |
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CO2 |
ANSI/UL 154-Latest Edition |
ANSI/NFPA 12-Latest Edition |
Dry Chemical |
ANSI/UL 299-Latest Edition |
ANSI/NFPA 17-Latest Edition |
Water |
ANSI/UL 626-Latest Edition |
ANSI/NFPA 13-Latest Edition |
Foam |
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ANSI/NFPA 11-Latest Edition |
Sprinklers |
ANSI/UL 199-Latest Edition |
ANSI/NFPA 13-Latest Edition |
Smoke Detectors |
ANSI/UL 268-Latest Edition |
ANSI/FPA 72B-Latest Edition |
Fire Detection Thermostats |
ANSI/UL 521-Latest Edition |
ANSI/FPA 72B-Latest Edition |
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1-6
To light the pilot light, refer to these instructions.
WARNING
Wait 5 minutes before attempting to relight the pilot to allow for any gas in the fryer to dissipate.
a.Open the gas supply valves to the fryer.
b.Open the fryer's door to gain access to the controls. Turn the thermostat control knob counterclockwise to the OFF position.
c.Turn the Unitrol valve knob to the PILOT position and push in on the
knob. Hold the knob in for approximately one minute to purge the air 
out of the line. Hold a flame to the pilot light until the pilot ignites. This 
may take a little while the first time you light the fryer because of air in 
the lines. Once lit, hold the knob in for approximately 60 seconds and 
then release. 
d.If the pilot goes out wait 5 minutes and repeat step c. If after three tries the pilot will not remain lit, refer to the operator troubleshooting section of this manual.
e.Turn the Unitrol valve knob counterclockwise to the ON position. 
f.Set the thermostat control knob to the desired temperature setting. 
g.The main burner will light and be controlled by the thermostat. 
h.Tocompletelyshutdownthefryer,turntheUnitrolvalveknobtopilot,pushinandcontinue turning to OFF.
1.5.2.1Pilot Flame Adjustment - The pilot flame should be adjusted to produce the proper millivolt output from the pilot sensing device. Millivolt output for the thermopile should be between 300 and 500 millivolts. This procedure is only necessary on the manual pilot ignition system. Figure 1-1 shows the pilot assembly with examples of the incorrect and correct pilot size. Example A illustrates a pilot flamesizethatistoosmalltoproducesufficientmillivoltoutput. ExampleBisthecorrectsizeforproper millivoltoutput.
a.This test requires a DC millivolt meter set to a scale of 0-1000mv.
b.Locate the thermopile wires coming from the thermostat/High Limit box going to the gas shut off valve. The wire insulation size decreases near the gas valve connections.
ENGLISH
1-7
c.Connect the negative (-) test probe to pilot bracket.
d.Connect the positive (+) test probe to to one of the High Limit terminal connections
e.Remove the pilot flame adjustment cover.
f.Turning the flame adjusting screw clockwise lowers the flame and the millivolt output. Turning the screw counterclockwise increases flame size and millivolt output.
g.Rotate the screw in the direction to achieve a reading of 400 ±50 mv for thermopiles.
NOTICE
Allow 3 to 5 minutes between flame adjustments to allow the reading to settle.
h. Replace the pilot flame adjusting screw cover.
1.5.3Main Burner System
For the burners to work, the gas supply valve must be open. The main burner receives gas from the main gas supply through the thermostatically controlled valve. When the thermostat is turned up the gas control valve opens. The pilot ignites the burners. The burner flame should be adjusted at the air collar (at the bottom of the burner) so the the flame are a soft blue color without lifting off the face of the burner.
1.5.3.1Gas Line Requirements- A properly installed gas supply system will deliver 7.0 ±2.0" w.c. natural gas (12.0 ±2.0" w.c. LP) to all appliances connected to the line, operating at full demand.
1.5.3.2Burner Adjustment - The burners must be adjusted to deliver optimum flame. Adjust the burner flame using the following procedure.
A B
Figure 1-1 Pilot Assembly, Flame Adjustment
1-8
a. |
Ensure that the Unitrol valve knob is in the OFF position. Remove the manifold pressure |
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tap plug and connect an accurate pressure gauge (range of 0-16" w.c. in 0.1" increments) |
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or manometer. |
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b. |
Light the pilot burner (see 1.5.2) for the unit being tested and adjust the thermostat to light |
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f. |
the main burners. |
ENGLISH |
To remove the pressure gauge, turn gas control valve to OFF. Remove the gauge and install |
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c. |
The installed pressure gauge reading should be the same, ±0.1", as that marked on the data |
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plate inside the door. If the pressure is correct go to step e, if not, adjust the pressure. |
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d. |
To adjust the pressure, remove the regulator adjustment screw cover (see Figure 1-3). Use |
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a flat tip screwdriver to adjust the screw until the proper pressure is reached. Turning the |
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screw clockwise will increase the pressure, counterclockwise will decrease the pressure. |
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e. |
When the pressure is correct, install the regulator adjustment screw cover. |
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the pressure tap plug. |
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g. |
Now that the pressure is set for proper operation, set the main burner flame. Unlock the air |
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collars by loosening the set screw for the collars. See Figure 5. Turn the Unitrol valve knob |
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to ON and turn thermostat to light the main burners. |
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h. |
Adjust the shape and size by raising or lowering the air collars to achieve a soft blue flame |
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with well defined inner cones. |
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i. |
When the flames have been properly adjusted, lock the collars in place with the set screw |
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provided. |
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1.5.4 Initial Cleaning
When the fryer is shipped, many of its parts are covered with a thin coat of oil for protection. Before the fryer is ready for cooking it must be cleaned. This will remove the oil coating and any foreign matter that may have accumulated during storage and shipment. Perform the cleaning as described below.
Figure 1-2 Gas Valve
Showing Location of the
Pressure Regulator and
Pilot Adjusters
1-9
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