Bakers Pride Oven ALF-F User Manual

Automatic Lift Fryer

MODELS ALF-F, & ALF-FC Service Manual

Serial Numbers 137733 and higher

Warranty Information

LIMITED ONE YEAR WARRANTY

BKI (The "Company") warrants to the original purchaser that at time of shipment from the Company factory, this equipment will be free from defect in materials and workmanship. Written notice of a claim under this warranty must be received by the Company within ONE YEAR from the date of installation, but no longer than ONE YEAR AND THREE MONTHS from date of shipment from the factory. Defective conditions caused by abnormal use or misuse, lack of or improper maintenance, damage by third parties, alterations by unauthorized personnel, acts of God, failure to follow installation and/or operating instructions, or any other events beyond the reasonable control of the Company will NOT be covered under this warranty. The obligation of the Company under this warranty shall be limited to repairing or replacing (at the option of the Company) any part, with the exception of lamps, fuses, and glass (which are not covered under warranty), which is found defective in the reasonable opinion of the Company. Any part found defective by the Company will be repaired or replaced without charge F.O.B. factory, Simpsonville, South Carolina or F.O.B. authorized BKI Distributor. The Company and/or its authorized representatives will assume the normal replacement labor expense for the defective part for the period of the warranty as stated above, excluding travel and/or other expenses incidental to the replacement of the defective part, where replacement work is performed during standard business hours and not subject to overtime, holiday rates, and/or any additional fees. IN NO EVENT SHALL THE COMPANY BE LIABLE FOR LOSS OF USE, LOSS OF REVENUE OR LOSS OF PRODUCT OR PROFIT OR FOR INDIRECT OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO, FOOD SPOILAGE OR PRODUCT LOSS. WARRANTY DOES NOT COVER GLASS BREAKAGE. THE ABOVE WARRANTY IS EXCLUSIVE AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, ARE EXCLUDED INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

REPLACEMENT PARTS

Any appliance replacement part, with the exception of lamps, fuses, and glass, which proves to be defective in material or workmanship within ninety (90) days of installation will be replaced without charge F.O.B. Factory, Simpsonville, SC or F.O.B. authorized BKI Distributor. The user shall have the responsibility and expense of removing and returning the defective part to the Company as well as the cost of reinstalling the replacement or repaired part.

Automatic Lift Fryer Table of Contents

Table of Contents

Table of Contents........................................................................................................................................1

Introduction .................................................................................................................................................2

Safety Precautions....................................................................................................................................2

Safety Signs and Messages.................................................................................................................2

Specific Precautions.............................................................................................................................3

Equipotential ground plane..............................................................................................................3

Full Disconnection............................................................................................................................3

Safe Work Practices.............................................................................................................................4

Safety Labels........................................................................................................................................8

Installation ...................................................................................................................................................9

Unpacking and Handling...........................................................................................................................9

Assembly and Mounting ...........................................................................................................................9

Wiring........................................................................................................................................................9

Initial Test and Adjustment .....................................................................................................................10

Operation ...................................................................................................................................................11

Controls and Indicators...........................................................................................................................11

Care of the Shortening............................................................................................................................14

ALF-F Operation.....................................................................................................................................14

Start-Up..............................................................................................................................................14

Cooking ..............................................................................................................................................16

ALF-FC Operation ..................................................................................................................................17

System Programming.........................................................................................................................17

Product Programming ........................................................................................................................19

Start-Up..............................................................................................................................................22

Cooking ..............................................................................................................................................22

Maintenance ..............................................................................................................................................24

Scheduled Maintenance.........................................................................................................................24

Filtering Procedure.............................................................................................................................25

Boil-Out Procedure.............................................................................................................................26

Filter Pad Replacement......................................................................................................................28

Troubleshooting......................................................................................................................................29

Replacement Parts....................................................................................................................................30

Assemblies..............................................................................................................................................30

Components............................................................................................................................................41

Accessories.............................................................................................................................................43

Wiring Diagrams........................................................................................................................................45

Notes ..........................................................................................................................................................54

Automatic Lift Fryer Introduction

Introduction

The ALF Fryer is compact, attractive and functional in design. It is constructed of a stainless steel fryer pot for cleaning ease. Exclusive BKI patented features and safety devices offer flexibility, efficiency and reliability plus PERFECTION IN FRYING!

The BKI name and trademark on this unit assures you of the finest in design and engineering -- that it has been built with care and dedication -- using the best materials available. Attention to the operating instructions regarding proper installation, operation, and maintenance will result in long lasting dependability to insure the highest profitable return on your investment.

PLEASE READ THIS ENTIRE MANUAL BEFORE OPERATING THE UNIT. If you have any questions, please contact your BKI Distributor. If they are unable to answer your questions, contact the BKI Technical Service Department, toll free: 1-800-927-6887. Outside the U.S., call 1-864-963-3471.

Safety Precautions

Always follow recommended safety precautions listed in this manual. Below is the safety alert symbol. When you see this symbol on your equipment, be alert to the potential for personal injury or property damage.

Safety Signs and Messages

The following Safety signs and messages are placed in this manual to provide instructions and identify specific areas where potential hazards exist and special precautions should be taken. Know a nd understand the meaning of these instructions, signs, and messages . Damage to the equipment, death or serious injury to you or other persons may result if these messages are not followed.

This message indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

This message indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

This message indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

This message is used when special information, instructions or identification are required relating to procedures, equipment, tools, capacities and other spe cial data.

Automatic Lift Fryer Introduction

Specific Precautions

Risk of fire exists if the oil level drops below 5mm of the maximum oil level.

Use of oil/shortening older than the manufacturers recommendations for life of the oil is prone to surge boiling and flash fires. Follow the oil manufacturers guidelines for the life cycle of oil/shortening.

Do not open the drain valve or the fill valve while the fryer is under pressure. Serious burns may result.

Follow operator instructions regarding effects of surge boiling of over-wet foods and proper load size.

This unit may incorporate components that contain Mercury. The use of Mercury relays is an industry standard.

Equipotential ground plane When a high current flows through a conductor, differences in potent ial appear between the conductor and nearby metallic surfaces near the appliance. As a result, sparks may be produced between the appliance and surrounding metal surfaces. These sparks could cause serious injury, damage, or fire.

BKI provides an Equipotential ground terminal for the connection of a bonding conductor after the installation of the appliance per lEC60417-1. This terminal is located on the inside of the Power Entry Supply box near the Earth connection and is marked with this symbol.

Full Disconnection

In accordance with Local and/or National wiring codes, the installer must provide a means of full disconnection under over voltage Category III conditions. An IEC approved cord and plug combination will meet this requirement.

Units not provided with a cord and plug do not meet this requirement. In accordance with Local and/or National wiring codes, the installer must provide the means of full disconnection.

The fryer is designed to hold a maximum of 48 lb (21.8 kg) of oil/shortening.

Automatic Lift Fryer Introduction

Safe Work Practices

Noncombustible Floors Only

Make sure your floor is noncombustible. Do not operate your fryer on floors that are wood, carpeted or have rubber mats.

• Placing your fryer on a combustible floor could cause a fire. Serious injury could result.

• Examples of noncombustible floors where you can safely place your fryer are concrete, tile, and ceramic.

Keep The Area Around Your Fryer Uncluttered

Make sure to keep the area around your fryer clear of any obstacles.

Serious injury can occur if you trip or fall near the fryer. You could be burned by hot shortening that splashes out of the fryer or by falling against the hot metal of the fryer.

Keep The Floor Around Your Fryer Clean Of Shortening

Make sure to keep the floor around your fryer clean of shortening and other liquids.

Serious injury can occur if you slip near your fryer. You could be burned by hot shortening that splashes out of the fryer or by falling against the hot metal of the fryer.

Keep The Casters Locked

To avoid spilling shortening, keep the casters locked. If any shortening spills near your fryer, clean it up immediately.

Automatic Lift Fryer Introduction

Do Not Overfill The Fryer With Shortening

Hot shortening and steam may escape and burn you if you put too much shortening in the fryer. Fill the fryer to approximately one inch below the fill marks that are inside the fryer pot. Heat the shortening. If needed, carefully add more shortening to bring the level to the fill marks.

Do Not Let Any Water Get Into The Fryer

Always remove excess moisture from food before placing it into the fryer basket. Water will cause the hot shortening to spatter. You could be burned.

Do Not Overload The Basket With Food

Hot shortening and steam may escape and burn you if you place too much food in the basket.

Wear Safe Clothing Appropriate To Your Job

Always wear your insulated mitts when handling the fryer basket or touch any hot metal surfaces. You received a pair of insulated mitts with your fryer. If you lose or damage your mitts, you can buy new ones at your local restaurant equipment supply store or from your local BKI Distributor.

Always wear non-skid shoes when working around the fryer or any other equipment that uses shortening. Never wear loose clothing such as neckties or scarves while operating your fryer. Keep loose hair tied back or in a hair net while operating your fryer.

Always wear appropriate personal protection equipment during the filtering process to guard against possible injury from hot oil.

Always wear appropriate personal protection equipment during the boil-out process to guard against possible injury from hot cleaning solution.

Automatic Lift Fryer Introduction

Keep this manual with the Equipment

This manual is an important part of your equipment. Always keep it near for easy access.

If you need to replace this manual, contact:

BKI

Technical Services Department P.O. Box 80400 Simpsonville, S.C. 29680-0400 Or call toll free: 1-800-927-6887 Outside the U.S., call 864-963-3471

Protect Children

Keep children away from this equipment. Children may not understand that this equipment is dangerous for them and others.

NEVER allow children to play near or operate your equipment.

Keep Safety Labels Clean and in Good Condition

Do not remove or cover any safety labels on your equipment. Keep all safety labels clean and in good condition. Replace any damaged or missing safety labels. Refer to the Safety Labels section for illustration and location of safety labels on this unit.

If you need a new safety label, obtain the number of the specific label illustrated on page 8, then contact:

BKI

Technical Services Department P.O. Box 80400 Simpsonville, S.C. 29680-0400 Or call toll free: 1-800-927-6887 Outside the U.S., call 864-963-3471

Automatic Lift Fryer Introduction

Be Prepared for Emergencies

Be prepared for fires, injuries, or other emergencies. Keep a first aid kit and a fire extinguisher near the equipment. You

must use a 40-pound Type BC fire extinguisher and keep it within 25 feet of your equipment.

Keep emergency numbers for doctors, ambulance services, hospitals, and the fire department near your telephone.

Know your responsibilities as an Employer

• Make certain your employees know how to operate the equipment.

• Make certain your employees are aware of the safety precautions on the equipment and in this manual.

• Make certain that you have thoroughly trained your employees about operating the equipment safely.

• Make certain the equipment is in proper working condition. If you make unauthorized modifications to the equipment, you will reduce the function and safety of the equipment.

Automatic Lift Fryer Introduction

Safety Labels

Automatic Lift Fryer Installation

Installation

Serious injury, equipment damage or death could result if attempting to install this fryer yourself. Ensure that an authorized BKI service agent installs the fryer.

Unpacking and Handling

It is the owners’ responsibility to file all freight claims with the delivering truck line. Inspect all cartons and crates for damage as soon as they arrive. If damage to cartons or crates is found, or if a shortage is found, note this on the bill of lading (all copies) prior to signing.

If damage is found when the equipment is opened, immediately call the delivering truck line and follow up the call with a written report indicating concealed damage to your shipment. Ask for an immediate inspection of your concealed damage item. Packaging material MUST be retained to show the inspector from the truck line.

Assembly and Mounting

1. Remove all packing materials from the interior and exterior of the fryer.

Risk of electric shock – Fryer must be secured to building structure. Follow restraining device instructions for proper installation.

2. Install an ANSI Z83.11/CGA 1.8 compliant restraining device (such as BKI part number FT0279) per the instructions below:

• Mount the wall attachment according the restraining device manufacturer instructions.

• Attach the spring-loaded hook on the restraining device to the eye-bolt mounted to the fryer

then attach the other spring-loaded hook to the wall attachment.

3. Lock the casters so the fryer does not move. Every time the fryer is used, make sure the casters are locked so the fryer cannot move.

4. Clean the fryer pot before filling with shortening.

5. Place the DRAIN handle in the CLOSED position.

Wiring

Electrocution, equipment failure or property damage could result if an unlicensed electrician performs the electrical installation. Ensure that a licensed electrician perform the electrical installation in accordance with local codes, or in the absence of local codes, with the National Electrical Code, ANSI NFPA 70-20XX.

This unit, when installed by an authorized BKI service agent, must be wired for use in accordance with all applicable local, state, and federal codes. For specific electrical requirements and conne ction s refer to the wiring diagram attached to the unit or provided in the Service Manual.

Automatic Lift Fryer Installation

Initial Test and Adjustment

1. Fill pot with shortening to about one inch below the mark.

Risk of fire exists if the oil level drops below the minimum oil level. The level of oil within the pot must not fall below 5mm of the maximum oil level.

Use of oil/shortening older than the manufacturers recommendations for life of the oil is prone to surge boiling and flash fires. Follow the oil manufacturers guidelines for lifecycle of oil/shortening.

Overfilling the fryer pot with shortening could lead to serious injury. Ensure that the fryer pot is filled with shortening only to the fill mark when shortening is hot. Do not use any shortening other than what is specified in this manual and do not overfill the fryer pot.

The fryer has a maximum temperature setting of 375º F/190º C (for ALF and ALF-F) or 390º F/200º C (for ALF-FC). Do not use oil/shortening with a flashpoint less than 554º F (290º C)

Use only high-quality shortening that has low moisture content, a high smoke point and no additives.

2. Place the FILTER/OFF/FRY switch to the FRY position. The shortening should begin to heat and begin to reach the fill mark inside the pot. Add more shortening as required to reach the fill mark. Refer to the troubleshooting section if this does not occur.

Automatic Lift Fryer Operation

Operation

Controls and Indicators

Refer to the figure and table below for an explanation of the fryer’s controls and indicators.

Automatic Lift Fryer Operation

Item # Description Function

1 Computer Used to set and activate product programs. 2 Momentary Basket

Switch

UP – Momentarily pushing the switch to this position causes the lift mechanism to rise. This is enabled only when the FILTER/OFF/FRY switch is in the FRY position.

DOWN – Momentarily pushing the switch to this position causes the lift mechanism to lower. This is enabled only when the FILTER/OFF/FRY switch is in the FRY position.

3 Rocker Switch FILTER – When placed in this position, power is applied to the

motor and shortening is pumped into the pot directly or thru the fill hose.

OFF – When placed in this position, power is removed from the pump motor, heating elements and lift mechanism.

FRY – When placed in this position, power is supplied to the

control panel, heating elements and lift mechanism. 4 Thermostat Knob Used to set the temperature of the shortening. 5 Thermostat Light Illuminates until the set temperature of the shortening has been

reached. 6 Digital Timer The digital timer consists of an LED, display, beeper and 8

buttons described below:

LED indicator Prior to the start of a timing cycle the LED will be OFF. When

running a timing cycle the LED will flash. At the end of a timing

cycle the LED will turn ON steady. When idle the LED is off.

TIME SELECT (2

arrow buttons)

Two arrow buttons on the front panel are used to set the time.

Hold the UP ARROW button down to increase the time. The

longer the button is held down, the faster the rate at which the

time will increase. The DOWN ARROW button is used in the

same manner as the UP ARROW button except it will cause the

time to decrease. The time is increased or decreased in 30-

second increments.

START/STOP

button

Starting the Timer - Pressing this button while the timer is not

active will cause the timer to begin counting down the time on the

display.

Stopping the Timer - Pressing this button while the timer is

active will stop the timer from counting down and display the

remaining time. Time cannot be changed with the TIME SELECT

buttons at this point. If this button is pressed again the timer will

continue counting down from the point it was stopped.

Resetting the Timer - Pressing and holding this button for longer

than two (2) seconds will reset the timer and the display will return

to the original starting time. At this point, time can be changed

using the TIME SELECT buttons or the preset buttons.

Canceling The STIR OIL Function - Pressing this button cancels

the STIR OIL function while it is active.

Automatic Lift Fryer Operation

Item # Description Function

ALARM button This button allows the user to set an elapsed time at which the

internal alarm will sound during a cycle. The time is set by

pressing and holding the ALARM button while using the UP and

DOWN arrows to change the time. The controller will limit the

alarm time to be less than the currently programmed interval cycle

time. The default alarm time is 0:00 which disables it. The ALARM

time is saved on power down in the same manner as the last

interval time. When a time cycle is running and the alarm time has

elapsed the internal alarm will sound for 10 seconds. For

example, a cycle time 10:00 and alarm time of 2:00 would cause

the alarm to sound for 10 seconds once the controller has counted

down from 10:00 to 8:00. This button is used to cancel the STIR

OIL alarm. This button is also used to reconfigure the STIR OIL

Function.

A, B, C, D preset

buttons

These buttons are used to save and recall preset cycle and alarm

times, saving operator time and minimizing error when changing

interval cycle times and alarm times. To save the current interval

and alarm times into one of the preset locations, press and hold

the A, B, C, or D preset button for 2 seconds and the controller will

double chirp to indicate the times have been saved. To recall any

preset time, press and quickly release the appropriate button and

the time values are loaded and displayed. These buttons are also

used to reconfigure the STIR OIL function.

Beeper A beeper sounds when the timer counts down to 0. Pressing the

START/STOP button stops the beeper and resets the timer

causing the display to return to the original starting time. At this

point, time can be changed using the TIME SELECT buttons or

the preset buttons. The beeper will also sound for 10 seconds if

the alarm time has elapsed during a timing cycle. When the STIR

OIL function begins the beeper will sound until the ALARM or

START/STOP button is pressed.

Display Used to display the time. It also displays the words “STIR” then

“OIL” in .5 second intervals until the ALARM or START/STOP

button is pressed. 7 High Limit Reset

Switch

Located under the control panel. If the heating elements inside the

pot reach an unsafe temperature, power is automatically removed

from the control panel and elements. Pressing this switch returns

power to the control panel and elements. 8 Drain Lever DRAIN OPEN – When placed in this position, the drain valve

opens and shortening in the pot drains into the vat. Also power is

removed from the control panel and elements.

DRAIN CLOSED – When placed in this position, the drain valve is

closed to prevent shortening from draining from the pot. 9 Fill Lever FILL THRU POT – When placed in this position, shortening can

be pumped automatically from the vat to the pot if the rocker

switch is in the FILTER position.

FILL THRU HOSE – When placed in this position, shortening can

be pumped from the vat to the pot via a connected hose if the

rocker switch is in the FILTER position.

10 Rinse Hose Connector Used to connect the Rinse hose for cleaning and refilling the pot. 11 Pump Motor Reset

Switch

If the motor overheats while filtering, it will automatically shut off.

Wait 15 minutes to allow motor to cool before pressing this switch.

Automatic Lift Fryer Operation

Care of the Shortening

To extend the life of your shortening, for the best possible flavor in your products, and for economy and efficiency of operation, we urge you to follow these recommendations:

1. Use only high-quality frying shortening without additives, of low moisture content and with a high smoke point.

2. Press excess moisture from products before breading. The more moisture released in the shortening, the quicker it will break down.

3. Filter at least once a day or once every three loads during frequent cooking.

4. Clean any residue or crust formations from the sides and bottom of the pot each time you filter the shortening.

5. Add fresh shortening as needed to maintain the proper shortening level TO THE FILL MARK ON THE POT WALL.

6. DO NOT HOLD SHORTENING AT HIGH TEMPERATURE when the fryer is not in use. If you expect an elapsed time of one hour or more between cooking, press the “0” button on the ALF-FC model. On the ALF-F, set the thermostat to 150º F.

7. Shortening changes are determined by the quantity and type of food prepared. Excessive boiling and foaming are definite signs of shortening breakdown.

8. After you have finished frying for the day, filter the shortening and replace the filter pad. Also, thoroughly clean the pot of sediment and crumbs and empty the condensate pan.

ALF-F Operation

Start-Up

1. Make sure the main drain valve is closed.

2. Fill pot with shortening to about one inch below the fill mark.

Risk of fire exists if the oil level drops below the minimum oil level. The level of oil within the pot must not fall below 5mm of the maximum oil level.

The fryer has a maximum temperature setting of 375º F/190º C (for ALF and ALF-F) or 390º F/200º C (for ALF-FC). Do not use oil/shortening with a flashpoint less than 554º F (290º C)

Use only high-quality shortening that has low moisture content, a high smoke point and no additives.

Automatic Lift Fryer Operation

3. The digital timer has a STIR OIL function that operates in one of four reconfigurable modes. If the timer needs to be reconfigured, follow step a. If the timer does not need to be reconfigured, follow step b.

a. Press and hold the ALARM button and at the same time place the FILTER/OFF/FRY switch

in the FRY position. The display will show the word “STIR” until the ALARM button is released. When the button is release the display will show the current configuration mode. To change this mode select the timer key that represents the mode you want. Refer to the table below:

KEY DISPLAY MODE DESCRIPTION

A -ALB -OFF

New or unchanged timer. Alarm sounds at the end of the internal 6 minute countdown. Defeats the STIR OIL function. Timer operates as if it had no STIR OIL

function. C PrES STIR OIL function for all Pressure Fryers. D LiFT STIR OIL function for all Autolift Fryers.

The display will now show the selected mode. Proceed to step c.

b. Once the fryer is filled with shortening, place the FILTER/OFF/FRY switch in the FRY

position.

c. Unless the STIR OIL function is operating in the –OFF mode, the digital timer activates a

STIR OIL function and begins an internal six minute countdown (not displayed). At the end of the internal countdown, the display shows the words “STIR” then “OIL” in .5 second intervals and the alarm sounds. Depress the ALARM button and stir the shortening freely while it is heating.

IMPORTANT! Before the first cooking operation each day, stir the shortening freely while it is heating to provide a balanced shortening temperature for excellent results with the first cooking. Failure to do this can result in a crusty skin on the product surface with an undercooked product internally. In addition, in some cases, failure to stir the shortening while it is initially heating may cause the HI-LIMIT safety device to disable the power due to a false overtemperature condition.

4. Set the thermostat to the desired cook temperature. The temperature light will go on. When the temperature is reached, the light will go off. The light will continue to cycle on and off as the fryer maintains the set temperature.

5. Raise the basket to the top position by depressing the basket switch to the UP position.

6. Press and hold the TIME SELECT arrow buttons on the digital timer until the desired cook time is displayed or recall a preset time by quickly pressing the appropriate preset button.

7. The shortening will heat and begin to reach the fill mark inside the pot. Add more shortening as required to reach the fill mark.

Automatic Lift Fryer Operation

Cooking

1. Ensure that the Start-Up procedures have been performed.

2. When frying chicken, lower the basket into the shortening by depressing the basket switch to the DOWN position.

Hot shortening may splash out of the pot causing severe injury when dropping chicken into pot. Carefully drop pieces of chicken into pot to prevent shortening splashes.

3. Carefully drop the chicken in the shortening one piece at a time starting with thighs and drumsticks. The fryer is designed to accommodate 32 pieces of chicken.

4. Activate the timer by pressing the START/STOP button on the digital timer. The timer will begin the count down.

5. At the end of the frying cycle, the digital timer beeper will sound and the basket will automatically rise to its top position. Press the START/STOP button on the digital timer.

6. Allow the basket to drain.

Failure to use the insulated mitts will result in injury. Always use the insulated mitts when handling the hot fry basket.

7. Remove basket from the lift and empty carefully.

8. Return the basket to the lift.

9. Remember to filter the shortening at least every third frying cycle load. Refer to the procedure in this manual. Also filter the shortening and clean the fryer at the end of each day. If you do not plan to use the fryer for an hour or more, turn the thermostat down to 150°.

10. When you have finished frying for the day, turn the FILTER/OFF/FRY switch to the OFF position.

+ 42 hidden pages

Bakers Pride Oven ALF-F User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual