BKI SV9403 Installation Manual

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Gas Pressure Fryer

MODELS LGF, LGF-F, & LGF-FC Installation and Operation Manual

Serial Numbers 109576 and higher

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Warranty Information

LIMITED ONE YEAR WARRANTY

BKI (The “Company”) warrants to the original purchaser/user, 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 given within ONE YEAR AND THREE MONTHS from date of shipment from the factory. Defective conditions caused by abnormal use or misuse, lack of maintenance, damage by third parties, alterations by unauthorized personnel, acts of God, failure to follow installation instructions or any other events beyond the control of the company will NOT be covered under Warranty. The obligation of the Company under this Warranty shall be limited to repairing or replacing (at the option of the company) any part which is defective in reasonable opinion of the Company. The user will 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.

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 DAM AGES 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. THIS WARRANTY SHALL APPLY ONLY WITHIN THE CONTINENTAL UNITED STATES, ITS TERRITORIES, AND POSSESSIONS AND IN CANADA.

LIMITED NINETY DAY LABOR WARRANTY

All labor necessary to repair or replace factory defective parts will be performed, without charge, to the end user, by service personnel of a BKI Authorized Distributor during the first ninety days after the date of installation of the new equipment.

Replacement parts: Any appliance replacement part, except lamps and fuses, which proves to be defective in material or workmanship within 90 days from date of original installation will be repaired or replaced without charge F.O.B. Factory, Simpsonville, S.C. or F.O.B. authorized distributor.

The purchaser must post, in a prominent location, instructions to be followed in the event the user smells gas. This information shall be obtained by consulting the local gas supplier.

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

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operation and maintenance instructions thoroughly before installing or servicing this equipment.

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Gas Pressure Fryer Table of Contents

Table of Contents

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

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

Safety .................................................................................................................................................................... 2

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

Safe Work Practices ......................................................................................................................................... 3

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

Operation................................................................................................................................................................ 10

Controls and Indicators ....................................................................................................................................... 10

Care of the Shortening........................................................................................................................................ 12

LGF and LGF-F Operation.................................................................................................................................. 13

Start-Up (LGF and LGF-F).............................................................................................................................. 13

Cooking (LGF and LGF-F).............................................................................................................................. 13

LGF-FC Operation............................................................................................................................................... 15

System Programming ..................................................................................................................................... 15

Product Programming..................................................................................................................................... 17

Start-Up (LGF-FC).......................................................................................................................................... 19

Cooking (LGF-FC) .......................................................................................................................................... 20

Recipes................................................................................................................................................................ 21

Operation After Gas or Power Outage................................................................................................................ 23

Normal Shutoff .................................................................................................................................................... 23

Installation.............................................................................................................................................................. 24

Inspection for Shipping Damage......................................................................................................................... 24

Preparation.......................................................................................................................................................... 24

Location and Clearance ...................................................................................................................................... 25

Installation Procedure.......................................................................................................................................... 25

Initial Test and Adjustment.................................................................................................................................. 26

Gas Conversion Instructions............................................................................................................................... 27

Maintenance........................................................................................................................................................... 28

Scheduled Maintenance...................................................................................................................................... 28

Safety Pop Valve Procedure........................................................................................................................... 29

Filtering Procedure.......................................................................................................................................... 30

LGF-F and LGF-FC.................................................................................................................................... 30

LGF............................................................................................................................................................. 31

Boil-Out Procedure ......................................................................................................................................... 32

Filter Pad Replacement .................................................................................................................................. 34

Troubleshooting................................................................................................................................................... 35

Notes....................................................................................................................................................................... 36

Appendix A............................................................................................................................................................. 37

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Gas Pressure Fryer Introduction

Introduction

The LGF Pressure 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 PRESSURE 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 instruction s 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

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 and un derstand 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 special data.

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Gas Pressure Fryer Introduction

Safe Work Practices

Do Not Store Or Use Anything Flammable Near The Fryer

Your pressure fryer is powered by either natural gas or LP gas. Do not store or use gasoline or any flammable liquids or vapors near this or any other appliance. Flammable materials will burn easily. Letting any flammable liquid or vapor get too close to the fryer could cause an explosion or fire. Serious injury could result. Examples of flammables that you should not store near the fryer are gasoline, paint, thinners or removers, gas tanks, and cleaning materials.

Use Gas Safely-- Avoid Danger

Gas can be a dangerous fuel if not handled safely. Make sure to ventilate the fryer properly. If the fryer is not properly

ventilated, carbon monoxide can be released around the fryer. Asphyxiation or suffocation can occur if gas is not ventilated properly.

Before using this appliance for the first time, contact your local gas supplier for instructions about what to do if you smell gas. Post those instructions somewhere near the fryer, so that everyone who uses or works near the fryer knows what to do if they smell gas.

Beware of High Voltage

This equipment uses high voltage. Serious injury can occur if you or any untrained or unauthorized person installs, services, or repairs this equipment. Always Use an Authorized Service agent to Service Your Equipment.

Use the Fryer On 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.

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Gas Pressure Fryer Introduction

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 Lid Closed When The Fryer Is Not In Use

Hot shortening can splash if someone moves the fryer or bumps into it. Serious injury can occur if hot shortening splashes out of the fryer.

Do not lean, sit or stand on the fryer or perform any maintenance or cleaning duties while the fryer or the shortening is hot. You could be burned.

Keep The Casters Locked

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

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.

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Gas Pressure Fryer Introduction

Always Make Sure The Lid Hook Is Latched When Closing The Fryer

To make sure the lid hook is latched properly, press down the lid until the hook snaps shut. Hot shortening and steam can escape if the lid hook is not latched properly. You could be burned.

Always Tighten The Spin Handle When Closing The Fryer

Hot shortening and steam can escape if you do not tighten the spin handle properly. You could be burned. Line up the orange knobs on the fryer lid handle and the front hook when tightening.

Do Not Over-Tighten The Spin Handle

You could damage the fryer.

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.

Never Loosen The Spin Handle Until The Pressure Gauge Is At Zero

Steam may escape suddenly if you loosen the spin handle before the gauge is at zero. If steam escapes suddenly, you could be burned.

After the pressure gauge is at zero, wait 5 seconds. Then loosen the spin handle slowly to open the lid of the fryer. By doing this, the steam will escape slowly and you will not be burned.

Seal The Safety Valve Properly

To seal the safety valve, lift the arm on the side of the valve. Then release it. The valve should snap closed. Hot steam can escape from the valve and you could be burned if you do not seal the valve properly.

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Gas Pressure Fryer Introduction

Keep Away From The Vent

Hot steam escapes from the vent continuously when you are using your fryer. You could be burned if you get too close to the vent.

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

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Gas Pressure 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.

Do Not Smoke Near The Fryer.

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Gas Pressure Fryer Introduction

Safety Labels

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Gas Pressure Fryer Introduction

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Gas Pressure Fryer Operation

Operation

Controls and Indicators

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

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Gas Pressure Fryer Operation

Item Description Function

1 Pressure Gauge Indicates the pressure inside the pot. 2 Spin Handle Used to tighten the lid to the pot once it is latched. 3 Pop Safety Valve lever Used to release pressure periodically to prevent the seat from sticking. 4 Computer Used to set and activate product programs. 5 Rocker Switch FILTER – When placed in this position, power is applied to the motor and

shorting is pumped into the pot directly or thru the fill hose. OFF – When placed in this position, power is removed from both the pump

motor and gas system. FRY – When placed in this position, power is supplied to the thermostat

and gas system. 6 Thermostat Knob Used to set the temperature of the shortening. 7 Thermostat Light Illuminates when the thermostat calls for heat. Extinguishes when the

shortening temperature is reached. 8 Analog Timer The analog timer consists of a light, dial, switch and buzzer described

below:

Light – Illuminates when the timer has been started and is counting down.

Cuts off when the timer is stopped.

Timer Dial – Used to set and display the time.

Timer Switch (ON/OFF) – Used to cut the timer on and off. To prevent

damage to the timer, always turn the timer switch OFF before setting the

timer dial.

Buzzer – A buzzer sounds when the timer counts down to 0. Placing the

timer switch to the OFF position will stop the buzzer. 9 High Limit Reset Switch If shortening inside the pot reaches an unsafe temperature, power is

automatically removed from the control panel and the gas system shuts

off. Pressing this switch returns power to the control panel and resets the

gas system. 10 Gas Control Valve Switch ON – Allows gas to flow when the FILTER/OFF/FRY switch is set to the

FRY position and the thermostat calls for heat.

OFF – Prevents gas flow regardless of FILTER/OFF/FRY switch and

thermostat settings. 11 Drain Lever DRAIN OPEN – When placed in this position, the drain valve opens and

shortening drains into the vat. Also power is removed from the control

panel and gas system.

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

to prevent shortening from draining into the pot. Also power is restored to

the control panel and gas system. 12 Fill Lever FILL THRU POT – When placed in this position, shortening will be pumped

from the vat to the pot if the rocker switch is in the FILTER position.

FILL THRU HOSE – When placed in this position, shortening will be

pumped from the vat to the pot via a fill hose if the rocker switch is in the

FILTER position. 13 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. 14 Rinse Hose Connector Used to connect the Rinse hose for cleaning and refilling the pot.

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Gas Pressure Fryer Operation

Care of the Shortening

Solid shortening should always be returned to the filter vat while in the liquid state. If this is not done, it will have to be heated to a liquid state. When using solid shortening, the fryer must be equipped with a pump heater. After filtering with solid shortening, the filter lines must be completely emptied of shortening. The pump heater will take care of any residual shortening in the pump, but cannot melt all of the shortening in the filter lines. The pump heater accessory may be purchased separately from BKI.

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 expe ct an elapsed time of one hour or more between cooking, close the lid and pre ss the “0” button on the LGF-FC model. On Models LGF and LGF-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.

9. 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 to disable the power due to a false overshoot condition.

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Gas Pressure Fryer Operation

LGF and LGF-F Operation

Start-Up (LGF and LGF-F)

1. Make sure the main drain valve is closed.

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

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

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.

3. Place the gas control ON/OFF switch in the ON position.

4. Place the FILTER/OFF/FRY switch in the FRY position.

5. Set the thermostat to the desired 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 tries to maintain the set temperature.

6. Set the correct cook time. To prevent damage to the timer, always turn the timer switch OFF before setting the timer dial.

7. 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.

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 to disable the power due to a false overshoot condition.

Cooking (LGF and LGF-F)

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

2. When frying chicken, connect the basket handle and lower the basket into the shortening in the fryer pot.

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.

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

4. Lift the basket approximately 2 to 3 inches (6.35 cm.) above the shortening and shake it. This keeps the food from sticking together and causing white spots on the cooked food.

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Gas Pressure Fryer Operation

Hot shortening may splash out of the pot causing severe injury when lowering basket into pot. Carefully lower basket into pot to prevent shortening splashes.

5. Slowly lower the fryer basket into fryer pot and remove the detachable handle.

6. Close the lid. Make sure the lid hook latches securely under the catch.

7. Tighten the spin handle until the lid is firmly sealed. Then line up the orange knob on the spin handle with the orange knob at the front of the fryer.

8. Activate the timer by placing the timer switch in the ON position to begin the countdown.

9. At the end of the frying cycle the timer buzzer will sound and the fryer will automatically release pressure into the baffle box. Set the timer to OFF. If the timer knob is set at 0, the timer will continue to buzz regardless of the position of the ON/OFF switch.

10. When the pointer on the pressure gauge is at zero, wait 5 seconds then slowly turn the spin handle counterclockwise to break the seal around the lid. The fryer has a locking pin that prevents turning the spin handle until the pressure drops to zero. Do not force the spin handle to open the lid.

11. Slowly open the lid.

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

12. Connect the basket handle then lift the basket and hang it on the front of the fryer pot to drain.

13. Empty the basket.

14. 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° F and close the lid.

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

16. Place the gas control ON/OFF switch in the OFF position.

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Gas Pressure Fryer Operation

LGF-FC Operation

System Programming

Use the following figure and table to set options that apply to each product programs.

Figure 1. System Programming Sequence

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Gas Pressure Fryer Operation

Table 1. System Programming Procedure

STEP ACTION DISPLAY COMMENTS

1 Press the FILTER/OFF/FRY

switch to FRY. 2 Press PROG on the keypad. PROGRAM CODE 3 Input 1712 and ENTER. PROGRAM SYSTEM 4 Press ENTER. PROGRAM DEGREES

5 Press TOGGLE/CLEAR until the

desired option is displayed. 6 Press ENTER. PROGRAM APL TYPE

7 Press TOGGLE/CLEAR until the

desired option is displayed. 8 Press ENTER. PROGRAM MELTCYCL

9 Press TOGGLE/CLEAR until the

desired option is displayed. 10 Press ENTER. PROGRAM GLBLFLTR

11 Press TOGGLE/CLEAR and

input the number of fry cycles

you want to complete among all

product programs before

enabling filter lockout. 12 Press ENTER. PROGRAM SYSTEM 13 Press PROG to exit the

programming mode.

PROGRAM DEGREES XX refers to the temperature scale

PROGRAM APL TYPE XX refers to the appliance type you

PROGRAM MELTCYCL XX refers to the melt cycle option

PROGRAM GLBLFLTR XX refers to the number of program

LOW

This command allows you to choose the temperature scale

°F

option you want to use. The display will show either show °F or °C.

you have chosen. This command allows you to

GAS

YES

LOW

choose the appliance type you are using. The display may show ELECTRIC, GAS OR ALF.

have chosen. This command allows you to set

the melt cycle option. This is normally set to yes if you are using solid shortening. The display will show either YES or NO.

chosen. This command allows you to

specify the total number of fry cycles to complete among all product programs before a message is displayed reminding you to filter the shortening (filter lockout).

cycles you want to complete among all product programs before filtering the shortening.

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Gas Pressure Fryer Operation

Product Programming

Use the following figure and table to set a maximum of eight product programs. The product programs must be set before cooking can begin.

Figure 2. Product Programming Sequence

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Gas Pressure Fryer Operation

Table 2. Product Programming Procedure

STEP ACTION DISPLAY COMMENTS

1 Press the FILTER/OFF/FRY

LOW

switch to FRY. 2 Press PROG on the keypad. PROGRAM CODE 3 Input 1724 and press ENTER. PROGRAM PRODUCT # 4 Select the program product

number (1-8). 5 Press ENTER. PROGRAM TIME1

PROGRAM PRODUCT X X refers to the program number

you selected. This command allows you to

00:00

specify the cooking time for this stage. The time displayed may be a previously programmed value.

6 Press TOGGLE/CLEAR and

input the number of minutes you

PROGRAM TIME1

XX:XX

XX:XX refers to the number of minutes you input.

want to cook. 7 Press ENTER. PROGRAM TEMP1

000 °F

This command allows you to specify the cooking temperature for this stage. The temperature displayed may be a previously programmed temperature. The temperature scale may also display °C depending on the system option that is set.

8 Press TOGGLE/CLEAR and

input the cooking temperature for

PROGRAM TEMP1

XXX °F

XXX refers to the cooking temperature you input.

product to be cooked. 9 Press ENTER. PROGRAM TEMPCOM1

FLEX TIME

This command enables you to select whether or not time is allowed for the fryer to recover from temperature loss while cooking during this stage. The FLEX TIME option will allow the fryer to recover from temperature loss.

10 Press TOGG LE/CLEAR until the

desired option is displayed. 11 Press ENTER. PROGRAM VALVE1

PROGRAM TEMPCOM1 XX refers to the temperature

compensation option selected. This command allows you to

CLOSED

specify whether the solenoid valve will be open or closed during this stage.

12 Press TOGG LE/CLEAR until the

desired option is displayed.

PROGRAM VALVE1 XX refers to the solenoid valve

option selected. OPEN is used for Models ALF and BLF Automatic Lift fryers. If your program requires the solenoid valve to be closed while cooking, choose the CLOSED option.

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Gas Pressure Fryer Operation

STEP ACTION DISPLAY COMMENTS

13 Repeat steps 5-12 when

programming stages 2, 3, 4 and

5 for Electric and Gas appliance

types.

Repeat steps 5-10 when

programming stages 2, 3, 4 and

5 for an ALF appliance type. 14 Press ENTER. PROGRAM PREALARM

00:00

15 Press TOGGLE/CLEAR and

input the prealarm minutes. 16 Press ENTER. PROGRAM FILTER 0This command allows you to

17 Press TOGGLE/CLEAR and

input the number of fry cycles

you want to complete before

enabling filter lockout. 18 Press ENTER. PROGRAM PRODUCT # 19 If you wish to input more

programs, proceed by pressing

the next program number and

follow steps 5 through 18 or

press PROG to exit the

programming mode.

PROGRAM PREALARM

XX:XX

PROGRAM FILTER XX refers to the number of program

The time and temperature of each stage has to be less than the preceding stage.

This command allows you to specify the number of minutes before the end of the cooking time (for each stage) until the alarm sound The prealarm value displayed may be a previously programmed value.

XX:XX refers to the prealarm minutes you input.

specify the number of fry cycles you want to complete for this program before a message is displayed reminding you to filter the shortening (filter lockout). The filter value displayed may be a previously programmed value.

cycles you want to complete before filtering the shortening.

Start-Up (LGF-FC)

1. Make sure the main drain valve is closed.

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

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

3. Place the gas control ON/OFF switch in the ON position.

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Gas Pressure Fryer Operation

4. Place the FILTER/OFF/FRY switch to the FRY position. LOW will appear on the computer display. 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.

Cooking (LGF-FC)

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

2. Press the desired program number on the keypad. The computer will still display "LOW". The fryer will begin to heat to the temperature that has been factory preset. When "READY" appears on the display, the fryer is up to the desired temperature and the product can be loaded.

3. When frying chicken, connect the basket handle and lower the basket into the shortening in the fryer pot.

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.

4. 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.

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

5. Lift the basket approximately 2 to 3 inches (6.35 cm.) above the shortening and shake it. This keeps the food from sticking together and causing white spots on the cooked food.

Hot shortening may splash out of the pot causing severe injury when lowering basket into pot. Carefully lower basket into pot to prevent shortening splashes.

6. Slowly lower the fryer basket into fryer pot and remove the detachable handle.

7. Close the lid. Make sure the lid hook latches securely under the catch.

8. Tighten the spin handle until the lid is firmly sealed. Then line up the orange knob on the spin handle with the orange knob at the front of the fryer.

9. Press the desired program number a second time. The red light above the program number will flash and the computer will display “COOK”. This will start a countdown in minutes and seconds until the end of the cycle.

10. At the end of the cooking cycle, the computer will display "DONE" and signal with a series of audible "beeps". Press the selected number once again to stop the cook cycle. Fifteen seconds before the end of the cook cycle, the program will automatically release the pressure from the fryer. For your safety, the lid will not unlock, even at the end of the cook cycle, until the pressure has been fully released.

Hot steam will escape when you open the lid possibly causing severe injury. Keep your face and arms away from the fry pot.

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Gas Pressure Fryer Operation

11. Slowly turn the spin handle counterclockwise to break the seal around the lid. Your fryer has a locking pin that prevents turning the spin handle until the pressure drops to "0".

12. Slowly open the lid.

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

13. Connect the basket handle then lift the basket and hang it on the front of the fryer pot to drain.

14. Empty the basket.

15. 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.

16. Close the lid and press the 0 button. Idle 255°F will display. This will automatically hold the shortening at a cooler temperature.

17. To escape the idle mode, press the 0 button again and the fryer will heat to its original temperature.

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

19. Place the gas control ON/OFF switch in the OFF position.

Recipes

Fried Onion Rings

1. Take frozen onion rings from freezer or bread fresh onion rings with Imperial breading.

2. Place onion rings into fryer basket.

3. Close cover to begin pressure frying.

4. Cook for 4 minutes at 350°F for frozen product.

5. Cook for 3 minutes at 350°F for fresh product.

Potato Wedges

1. Wash and cut potatoes.

2. Season and bread each stick with Imperial breading.

3. Place potato wedges into fryer basket.

4. Close cover to begin pressure frying.

5. Cook for 7 to 8 minutes at 325°F depending on size.

French Fries

1. Take frozen french fries from freezer or wash and cut fresh potatoes.

2. Place french fries into fryer basket.

3. Close cover to begin pressure frying.

4. Cook for 4 to 6 minutes at 325°F depending on size.

Fresh Chicken

Use fresh 8 or 9-piece cut chicken. Use 2-1/2 to 3 pounds for best results.

1. Rinse product under cold water.

2. Bread each piece with Imperial breading.

3. Place product into fryer basket.

4. Close the cover to begin pressure frying.

5. Cook for 12 minutes at 325°F.

Page 24

Gas Pressure Fryer Operation

Frozen Chicken ( MRB ) except wings

1. Take product from freezer.

2. Place product into fryer basket.

3. Cook for 3 minutes (open) at 325°F.

4. Add wings to fryer basket.

5. Close the cover to begin pressure frying.

6. Cook for 17 minutes at 325°F.

Fresh Chicken Wings

1. Rinse product under cold water.

2. Bread each piece with Imperial breading.

3. Place product into fryer basket.

4. Close cover to begin pressure frying.

5. Cook for 12 minutes at 325°F.

Chicken Wings (Frozen - 5 kilograms or 10 pounds)

1. Take product from freezer.

2. Place wings into fryer basket.

3. Close cover to begin pressure frying.

4. Cook for 8 minutes at 325°F or 9½ to 10 minutes at 320°F.

Chicken Drummettes

1. Take product from freezer.

2. Place drummettes into fryer basket.

3. Close cover to begin pressure frying.

4. Cook for 9 to 11 minutes at 325°F.

Whole Turkey (12 to 14 pounds)

1. Rinse and bread turkey with Imperial breading.

2. Place turkey into fryer basket.

3. Close cover to begin pressure frying.

4. Cook for 45 to 55 minutes at 300°F.

Whole Duckling

1. Rinse and bread duck with Imperial breading.

2. Place duck into fryer basket.

3. Close cover to begin pressure frying.

4. Cook for 20 to 25 minutes at 300°F.

Pork Chops

1. Bread each chop with Imperial breading.

2. Place pork chops into fryer basket.

3. Close cover to begin pressure frying.

4. Cook for 8 to 10 minutes at 325°F depending on size.

Cube Or Minute Steaks

1. Bread each steak with Imperial breading.

2. Place steaks into fryer basket.

3. Close cover to begin pressure frying.

4. Cook for 2 to 4 minutes at 325°F depending on size.

Milanese

It is best to use 5 to 7 ounce beef steaks.

1. Season and bread each steak as desired.

2. Place steaks into fryer basket.

3. Close cover to begin pressure frying.

4. Cook for 5 to 6 minutes at 325°F depending on size.

Page 25

Gas Pressure Fryer Operation

Fresh Shrimp

1. Season and bread shrimp as desired.

2. Place shrimp into fryer basket.

3. Close cover to begin pressure frying.

4. Cook for 2½ to 3½ minutes at 350°F depending on size.

Fresh Fish or Frozen Fish

For best results, use a tiered basket. The best fish for frying are Flounder, Cod, Walleyed Pike, or any other popular frying fish.

1. Bread each piece of fish as desired.

2. Place fish in tiered basket.

3. Close cover to begin pressure frying.

4. Cook for 5 to 7 minutes at 325°F depending on size for fresh fish.

5. Cook for 8 to 10 minutes at 325°F depending on size for frozen fish.

Corn On The Cob

Corn can be fried either plain or breaded.

1. Take frozen corn ears from freezer and rinse.

2. Bread with Imperial breading as desired.

3. Place corn ears into fryer basket.

4. Close cover to begin pressure frying.

5. Cook for 6 to 8 minutes at 325°F depending on size.

Egg Rolls (frozen)

1. Take egg rolls from freezer.

2. Place egg rolls into basket.

3. Close the cover to begin pressure frying.

4. Cook for 6 to 8 minutes at 325°F depending on size.

Operation After Gas or Power Outage

The fryer may shut off automatically if the gas supply is interrupted or the power goes out. If either of these conditions occur you should perform the following procedure:

For your safety, if the gas supply stops, or, if the power goes out, make sure to wait for at least five minutes before restarting your fryer. This allows time for any unburned gas to dissipate. (LP gas may take longer than five minutes.) If you smell gas, do not start your fryer.

1. Place the gas control ON/OFF switch in the OFF position.

2. Place the FILTER/OFF/FRY switch in the OFF position.

3. Wait at least five minutes to allow any gas that may have accumulated in the burner compartment to escape.

4. Follow normal operating procedures once the power or gas is restored.

Normal Shutoff

1. Place the FILTER/OFF/FRY switch in the OFF position.

2. Place the gas control ON/OFF switch in the OFF position.

3. Wait at least five minutes to allow any gas that may have accumulated in the burner compartment to escape.

Page 26

Gas Pressure Fryer Installation

Installation

Inspection for Shipping Damage

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.

Preparation

There are several things the installer must know before installing the fryer. These are listed below:

• The fryer installation must conform with city or county standards for gas appliances and gas piping. If your area does not have local codes, consult the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code, CSA B149.1. In Europe, city and country codes are enforced.

Do not attempt to test the gas pressure of your fryer. Pressure testing should be done only by an authorized Service Agent.

• During any pressure testing of the gas supply system, the fryer must be protected. The fryer and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of ½ psi (3.5 kPa). The fryer must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than ½ psi (3.5 kPa).

• The fryer must be electrically grounded to conform with the local code of your city or county. If your area does not have local codes, consult the latest version of the National Electrical Code ANSI/NFPA 70, or the Canadian Electrical Code, CSA C22.2. In EUROPE, city and country codes are enforced.

• A schematic diagram of the unit is glued to the back of either the left or right side panel.

• The Authorized Service Agent that installs your fryer must connect the cord set at the rear of the fryer to

an electrical source with a voltage matching that stamped on the name and rating tag. Refer to the wiring diagrams in this manual.

• Make sure a connector is used that complies with the Standard for Connectors for Movable Gas Appliances, ANSI Z21.69 • CSA 6.16.

• Make sure a quick-disconnect device is used that complies with the Standard for Quick-Disconnect Devices for Use With Gas Fuel, ANSI Z21.41 • CSA 6.9.

• In Europe, the installer must supply the gas supply connector.

• Make sure a restraining device is used that complies with the Standard for Commercial Gas Ranges,

ANSI Z83.11/CGA 1.8 (such as BKI part number FT0279) to guard against transmission of strain to the connector.

• Retain the manual for future reference.

Page 27

Gas Pressure Fryer Installation

Location and Clearance

Install your fryer in a well-ventilated area. This will ensure that the gas burns properly and will help prevent any fires. When deciding on a location for your fryer, remember the following:

• All gas-burning appliances need enough fresh air for combustion.

• Locate the fryer where it can be vented into an adequate exhaust hood. Your local gas utility must

approve your ventilation system. Consult a ventilation or heating company to help you design an adequate system that meets ventilation codes and standards for your city or county. In Europe, install according to local codes.

• Keep the fryer away from any combustibles such as curtains, wood paneling, boxes, or towels. The flue riser at the rear of the fryer should also be kept away from any flammable material.

• Use this fryer on non-combustible flooring only. Examples of non-combustible floors where you can safely locate your fryer are concrete, tile, and ceramic. Minimum clearance from combustible and noncombustible construction is 6 inches from the sides and 6 inches from the flue riser at the rear. DO NOT locate your fryer on floors that are wood, have rubber mats, or, are carpeted. In Europe, no less than 6" (15.24 cm.) from the rear and 0" to the sides of non-combustible walls.

• Keep the work area around the fryer free of objects that might block fresh air or that might cause a fire.

• Do not attach an extension to the exhaust stack. This may stop the burner from operating properly, cause

the burner to go off, or, cause other dangerous malfunctions. It may also cause a strong draft in the room. A draft can interfere with the burner.

• Do not locate the fryer near strong drafts. Keep the fryer away from doors that are opened and closed frequently.

Installation Procedure

Ensure that an authorized BKI service agent installs the fryer. An authorized BKI service agent should be a qualified gas service technician and a licensed electrician.

1. Remove the shipping packing clip from underneath the dead weight cap.

2. Replace the dead weight and cover.

Page 28

Gas Pressure Fryer Installation

Failure to restrain the fryer could allow it to move, causing hot shortening to spill out, or a possible break in the gas line causing an explosive condition.

3. 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.

Use appliance connectors and quick-disconnect devices that are in compliance with the applicable ANSI and CSA standards.

4. Attach an appliance connector to the fryer according to the instructions provided by the appliance connector manufacturer.

5. Connect the gas supply to the fryer. In Europe, the gas supplier must provide the gas hookup connecting line.

6. Lock the casters so the fryer does not move. Every time you use the fryer, make sure the casters are locked so the fryer cannot move. (In Canada: refer to caster codes CAN 1-6.10 M88 and CAN 1-6.9 M79.)

7. Turn on the gas at the gas supply valve.

8. Check for gas leaks from the gas supply to the fryer gas valve using a soap and water solution. If a leak is detected, tighten the connection where the leak occurs.

9. Connect fryer wiring according to the appropriate wiring diagram in this manual.

10. Apply power to the fryer.

11. Perform the following procedures provided in the Startup and Checkout section of the SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 SmartValve™ SYSTEM CONTROLS Installation Instructions (69-1004-2). Refer to Appendix A.

• Gas Leak Test

• Check and Adjust Pilot Flame

• Check and Adjust Gas Input Burner Ignition

Initial Test and Adjustment

1. Cut on the gas at the gas supply valve.

2. Place the DRAIN handle in the CLOSED position.

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

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

Page 29

Gas Pressure Fryer Installation

4. Place the gas control ON/OFF switch in the OFF position.

5. Place the FILTER/OFF/FRY switch in the OFF position.

6. Before you turn on the gas, wait at least five minutes to allow any gas that may have accumulated in the burner compartment to escape.

7. Place the gas control ON/OFF switch in the ON position.

8. 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.

Gas Conversion Instructions

To convert the gas system from a Natural Gas to LP Gas application or vice versa, contact the BKI Technical Service Department, toll free: 1-800-927-6887. Outside the U.S., call 1-864-963-3471.

Page 30

Gas Pressure Fryer Maintenance

Maintenance

Failure to comply with the maintenance below could result in a serious accident. Do not over-tighten the spindle assembly. (Only tighten to hold pressure.) Your fryer will need periodic maintenance and servicing. We strongly suggest that you

use only a service company that is authorized by BKI to do this work. The restraining device must always be connected when the appliance is in service.

Disconnect for movement, such as servicing or cleaning. Reconnect the re straint when fryer has been returned to its normal position.

Scheduled Maintenance

Use the following table to help manage scheduled maintenance activities.

FREQUENCY PERFORMED BY PART ACTIVITY

Each Fry Cycle

Daily

Weekly

User Pressure Gauge Check for proper display of cooking vat

pressure. Contact authorized BKI service agent if adjustment or replacement is required.

User Lid Gasket Check for unusual wear such as cracks

and deformation, and pressure leaks. Contact authorized BKI service agent if adjustment or replacement is required.

User Dead Weight

Assembly

User Filter Pad Replace filter pad. Refer to the

User Condensation

Pan

User Filter system Filter the shortening using the

User Safety Pop Valve Check for release of pressure and

User Fryer Pot Perform the boil-out procedure in this

Clean weight and orifices daily and check for wear.

procedure in this manual. Remove and drain.

procedure in this manual.

proper seal. Refer to the procedure in this manual.

manual.

Every 6 Months

Authorized BKI

Authorized BKI service agent

service agent

Acme Screw and Nut

Solenoid Valve Check that the valve is holding and

Hook, Catch, Spring

Connections, Fittings

Check for wear on the threads.

releasing pressure when the timer or computer activates it.

Check for wear and ease of operation.

Check for leakage while oil is pumping.

Page 31

Gas Pressure Fryer Maintenance

Safety Pop Valve Procedure

The safety pop valve should be blown under pressure periodically to prevent the seat from sticking.

Failure to use the insulated mitts will result in injury. Always use the insulated mitts when handling the arm on the safety valve.

1. After the pressure is up during a cooking cycle, use the insulated glove to lift the arm on the edge of the safety valve and let some steam escape. This will clean the valve.

2. Release the lever on the valve, and let it slam shut to seal the valve.

Page 32

Gas Pressure Fryer Maintenance

Filtering Procedure

Breaded foods require frequent filtering. An excess amount of breading left in the fryer pot will reduce the life of the shortening. We recommend the shortening be filtered after every three frying cycle loads. When the shortening starts to show signs of foaming and has a bad taste, do not use it. The fryer pot should be cleaned before refilling with new shortening. Best results for filtering are obtained while the sho rtenin g is hot. You should filter at the end of every business day. You should also remove and drain the condensation pan daily.

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

If the pump motor automatically shuts off while filtering, place the FILTER/OFF/FRY switch in the OFF position, wait 15 minutes, press the pump motor reset button, then follow the appropriate refill procedure below.

LGF-F and LGF-FC

1. Set the FILTER/OFF/FRY switch to OFF.

2. Remove the fryer basket.

3. Make certain that the filter pad is clean and not torn.

IMPORTANT: Make certain the vat cover is properly positioned underneath the drain valve. Also make certain the filter vat and filter screen is under the main drain valve before starting the filtering process.

4. Move the DRAIN handle slowly to the OPEN position so that the shortening starts to flow evenly. This

is to prevent excessive splashing of hot shortening.

5. When the pot is empty, place the DRAIN handle in the CLOSED position.

To refill the pot automatically, use the steps below:

Hot shortening may splash out of the pot causing severe injury when filling the pot if the lid is not closed. To prevent shortening splashes, close the lid before filling.

• Close the lid to prevent shortening splashes.

• Place the FILL handle to the THRU POT position.

• Position the FILTER/OFF/FRY switch to FILTER and shortening will automatically pump into the

pot.

• After 1 minute carefully open the lid to check the level of the shortening.

• Let the filter continue to pump the shortening until the fill mark in the fryer pot is reached or until

air starts bubbling through the shortening.

• As soon as air is seen in the shortening, first place the FILL handle to the THRU HOSE position then position the FILTER/OFF/FRY switch to OFF to prevent shortening degradation and prevent the filter pump and lines from filling up with shortening.

• Add new shortening if the fill mark has not been reached.

Page 33

Gas Pressure Fryer Maintenance

To refill the pot through the rinse hose, use the steps below:

• Make certain that the rinse hose is connected to rinse hose connector.

• Holding the hose by the handle, place hose nozzle inside the pot.

Hot shortening may splash out of the pot causing severe injury when filling the pot if the lid is not held down over the hose nozzle. To prevent shortening splashes, hold the lid down over the hose nozzle.

• Hold the lid down over the hose nozzle to prevent shortening splashes.

• Position the FILL lever in the THRU HOSE position.

• Position the FILTER/OFF/FRY switch to FILTER and shortening will automatically pump into the

pot.

• After 1 minute, hold the hose by the handle and carefully raise the lid to check the level of the shortening.

• Let the filter continue to pump the shortening until the fill mark in the fryer pot is reached or until air starts bubbling through the shortening.

• As soon as air is seen in the shortening, position the FILTER/OFF/FRY switch to OFF to prevent shortening degradation.

• Add new shortening if the fill mark has not been reached.

LGF

1. Set the FILTER/OFF/FRY switch to OFF.

2. Remove the fryer basket.

3. Make certain that the FKF filter unit or portable filter unit filter pad is clean and not torn.

4. Position the FKF filter unit or portable filter unit under the main drain valve and make sure it’s filter screen is in place.

5. Ensure that the FKF filter unit or portable filter unit is powered.

6. Move the DRAIN handle slowly to the OPEN position until the shortening starts to flow evenly. This will prevent excessive splashing of hot shortening.

7. When the pot is empty, place the DRAIN handle in the CLOSED position.

To refill the pot through the drain valve, use the steps below:

• Make certain that the braided hose (located on the drain valve) is connected to it’s mating part on

the FKF filter unit or portable filter unit.

Hot shortening may splash out of the pot causing severe injury when filling the pot if the lid is not closed. To prevent shortening splashes, close the lid before filling.

• Close the lid to prevent shortening splashes.

Page 34

Gas Pressure Fryer Maintenance

• Position the FILTER/OFF/FRY switch to FILTER and shortening will automatically pump into the

pot.

• After 1 minute carefully open the lid to check the level of the shortening.

• Let the filter continue to pump the shortening until the fill mark in the fryer pot is reached or until

air starts bubbling through the shortening.

• As soon as air is seen in the shortening, position the FILTER/OFF/FRY switch to OFF to prevent

shortening degradation and prevent the filter pump and lines from filling up with shortening.

• Add new shortening if the fill mark has not been reached.

To refill the pot through the rinse hose, use the steps below:

• Make certain that the rinse hose is connected to it’s mating part on the FKF filter unit or portable

filter unit.

• Holding the hose by the handle, place hose nozzle inside the pot.

• Hold the lid down over the hose nozzle to prevent shortening splashes.

• Position the FILTER/OFF/FRY switch to FILTER and shortening will automatically pump into the

pot.

• After 1 minute, hold the hose by the handle and carefully raise the lid to check the level of the

shortening.

• Let the filter continue to pump the shortening until the fill mark in the fryer pot is reached or until

air starts bubbling through the shortening.

• As soon as air is seen in the shortening, position the FILTER/OFF/FRY switch to OFF to prevent

shortening degradation.

• Add new shortening if the fill mark has not been reached.

Boil-Out Procedure

Boil-outs remove microscopic particles of carbon that build up on the walls of the fryer pot. To avoid eventual carbon build-up, off flavors, and shortening breakdown, boil-outs should be done once a week on each fry er following these procedures.

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

1. Position the FILTER/OFF/FRY switch to OFF.

2. Drain the clean shortening into an adequate storage container. (Allow the shortening to cool to room temperature before attempting storage.)

Page 35

Gas Pressure Fryer Maintenance

3. CLOSE the drain and fill the fryer pot with HOT water to the shortening level fill mark. Do not overfill by allowing the water level higher than the fill mark.

4. Add ½ cup (4 ounces) of BKI cleaner.

5. Wash down the inside of the pot and lid with the pot brush to loosen the sediment.

6. Set the temperature of the solution as follows:

• For an LGF or LGF-F – Position the FILTER/OFF/FRY switch to ON. Set the thermostat to a

temperature of 190º F.

• For an LGF-FC – Position the FILTER/OFF/FRY switch to ON. Press PROG (program), type 1733,

and press ENTER. The fryer pot will heat to a temperature of 190º F during the CLEAN cycle to allow the CLEAN function to be performed. NOTE: The fryer pot must be below 255º F to enter the CLEAN mode.

7. Bring the cleaning solution to a rolling boil and maintain the boil for 5 minutes.

8. Place the FILTER/OFF/FRY switch to OFF.

9. Scrub the inside of the fryer pot and inside of the lid again.

10. Before draining the cleaning solution, remove the filter bag, screen and pipe connections from the filter vat. This must be done before draining the cleaning solution. NEVER pump water or deterge nt through the filter system.

11. After 15 minutes, slowly open the drain valve. Drain the solution into the filter vat and discard.

12. Rinse the pot with hot water, using the pot brush to remove remaining sediment, drain and discard.

13. Close the drain and refill the fryer pot with hot water to the proper level.

14. Add approximately 4 to 6 ounces of distilled (white) vinegar to develop a neutralizing solution. Stir the solution briefly. Leave in the pot for three to five minutes and discard. NOTE: Foaming of shortening

after boil-outs is caused by failure to follow proper neutralizing procedures.

15. Repeat steps 12 through 14 as needed to remove all traces of cleaning solution.

16. Rinse the pot again with Cool water, drain and discard.

Damage to the fryer could result if the fryer pot is not completely dry before filling with shortening. Refill the fryer pot with shortening ONLY when it is completely dry.

17. Dry the fryer pot, lid, and filter vat COMPLETELY.

18. Close the main drain and fill with new shortening to the proper level.

Page 36

Gas Pressure Fryer Maintenance

Filter Pad Replacement

The filter pad must be replaced daily. If the shortening has a milky color when it is pumped into the pot, the filter pad should be replaced immediately.

If the filter pad is not properly closed, breading crumbs will get through the pad opening and clog the pump. Ensure that the filter pad is properly closed upon replacement.

1. Place the filter screen inside the filter pad.

2. Fold the end of the pad and seal with the bag clip.

Page 37

Gas Pressure Fryer Maintenance

Troubleshooting

Refer to the table below for troubleshooting information.

Problem Cause Possible Solution Pressure Loss or Not Releasing

Pressure

Shortening Heating Too Slowly

Bad thermostat or loose Filter System Not Working

Connections not tight Tighten the connections. If problems

Filter valve not open Contact an authorized BKI service agent Filter paper on screen

Motor hums, but does not

Motor and pump coupling No power to control panel Make sure drain valve is completely

Computer Hangs

Dead Weight Valve Leaking Clean the weight and orifice. If problems

persist, contact an authorized BKI service agent for corrective action.

Lid Gasket Leaking Contact an authorized BKI service agent

for corrective action. Solenoid Valve Leaking or Stuck

Safety Valve not seating Contact an authorized BKI service agent Gas pressure is low or isn’t

adjusted properly wires

Uncertain Press the reset button on end of pump

clogged with crumbs

pump

worn

Computer malfunction. Press and hold the Toggle/Clear button

After a period of time, it is possible that

the valve seat and/or plunger may stick or

wear. Activate the valve by starting a cook

cycle. You should hear a solid metallic

CLICK sound from the solenoid valve. If

you should hear no sound (or a slow

BUZZING CLICK), contact an authorized

BKI service agent for corrective action.

for corrective action.

Contact an authorized BKI service agent

for corrective action.

Contact an authorized BKI service agent

for corrective action.

and hi-limit reset button under control

panel. If problems persist, contact an

authorized BKI service agent for

corrective action.

persist, contact an authorized BKI service

agent for corrective action.

for corrective action.

Change filter paper. If problems persist,

contact an authorized BKI service agent

for corrective action.

Check for clogged pump. If problems

persist, contact an authorized BKI service

agent for corrective action.

Contact an authorized BKI service agent

for corrective action.

closed. If problems persist, contact an

authorized BKI service agent for

corrective action.

while moving the FRY/OFF/FILTER

switch from FRY to OFF and back to

FRY. If problems persist, contact an

authorized BKI service agent for

corrective action.

Page 38

Gas Pressure Fryer Notes

Notes

Page 39

Gas Pressure Fryer Appendix A

Appendix A

Gas Control Valve Instructions

Page 40

SV9401/SV9402/SV9403, SV9501/

SV9502/SV9503, SV9601/SV9602

SmartValve™

System Controls

INSTALLATION INSTRUCTIONS

APPLICATION

The SV9401/SV9402/SV9403, SV9501/SV9502/ SV9503, and SV9601/SV9602 SmartValve™ System Controls combine gas flow control and electronic intermittent pilot sequencing functions into a single unit. This product family offers several different intermittent pilot sequences for a wide range of applications. See Table 1 for specific sequences available. The Q3450 or Q3480 Intermittent Pilot hardware provides the low voltage ignition, flame sensor, and pilot burner. This system is suitable for application in a wide range of gas-fired appliances including furnaces, rooftop furnaces, boilers, unit heaters, infrared heaters, space heaters, water heaters, decorative appliances, and commercial cooking units. The specific application of the SmartValve™ System is the responsibility of the appliance manufacturer. See Table 2 for gas capacity and thread sizes.

Table 1. Ignition Sequence Description.

Model Type Prepurge (sec) Ignition Trial Time

SV9401/SV9501/SV9601 Continuous Retry — 90 seconds 5 minutes

SV9402/SV9502/SV9602 15 or 30 seconds

SV9403/SV9503 Single Trial with

All times increase by approximately 20 percent when used at 50 Hz.

Pilot flow stops at end of ignition trial unless pilot lights and proves.

Electrical Ratings:

System Transformer: 40 VA minimum NEMA-rated

transformer. Control systems using SV9601, SV9602, or other large secondary loads may require a larger transformer. Refer to the appliance manufacturer recommendation.

Voltage and Frequency: 24 Vac, 50/60 Hz.

Lockout

SPECIFICATIONS

WARNING

Fire or Explosion Hazard. Can cause severe injury, death or property damage.

The SV9401/SV9402/SV9403; SV9501/SV9502/ SV9503; SV9601/SV9602 provide direct replacement only. Use the Y8610 to convert standing pilot systems to electronic ignition systems.

Ignition Sequences: See Table 1 for available ignition

sequences.

Body Pattern: Straight through. See Table 2 for inlet and

outlet specifications.

Capacity:

See Table 2 for available gas flow capacities. Table 3 describes the acceptable ambient temperature

range for the SV9X01, SV9X02, and SV9X03 SmartValves.

Auto Reset Time

— 90 seconds N/A

Current draw at 24 Vac: 24V Hot: 1.25A nominal (1.5A

maximum) when igniter is powered. 24V Thermostat: See Table 4. Electronic Fan Timer Output: 0.1A maximum at 24 Vac.

Output is 8 Vac less than thermostat input voltage at

0.1A draw.

69-1004-2

Page 41

SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 SMARTVALVE™ SYSTEM CONTROLS

Table 2. Capacity and Inlet and Outlet Specifications.

Model

SV9401/SV9402/ SV9403

SV9501/SV9502/ SV9503

SV9501 1/2 NPT x 1/2

SV9601/SV9602

Size Inlet X Outlet

(in.)

1/2 x 1/2 NPT

inverted flare

1/2 x 1/2 NPT

1/2 x 3/4 NPT

3/4 x 3/4 NPT

Capacity based on 1000 Btu/ft3, 0.64 specific gravity at 1 in. wc pressure drop (37.3 MJ/m3,0.64 specific gravity natural gas at 0.25 kPa pressure drop).

Minimum regulation for LP gas is 15,000 Btuh.

Minimum regulation for LP gas is 40,000 Btuh

Capacity is reduced by 5 percent with the use of optional outlet screen.

Valves are guaranteed only at 77 percent of the rating.

Capacity (at 1 in. wc

pressure drop

/hr (2/3 m3/hr) 10 ft3/hrb (0.4 m3/hrb) 120 ft3/hr (3.4 m3/hr)

85 ft

/hr (4.2 m3/hr) 20 ft3/hr (0.6 m3/hr)c200 ft3/hr (5.7 m3/hr)

150 ft

/hr (3/7 m3/hr) 20 ft3/hr (0.6 m3/hr)c180 ft3/hr (5.1 m3/hr)

130 ft

/hr (6.8 m3/hr)e30 ft3/hr (0.8 m3/hr) 340 ft3/hr (9.6 m3/hr)

240 ft

/hr (7.6 m3/hr)e30 ft3/hr (0.8 m3/hr) 370 ft3/hr (10.5 m3/hr)

270 ft

/hr (7.6 m3/hr)e30 ft3/hr (0.8 m3/hr) 415 ft3/hr (11.8 m3/hr)

300 ft

Minimum Regulated

)

Capacity

Maximum R egulated

Capacity

Table 3. Model Number Suffix Letter Description.

Model No. Suffix Letter Ambient Temperature Range Pressure Regulator Type

H 0° F to 175° F (-18° C to +79° C) Slow opening

M -40° F to +175° F (-40° C to +79° C) Standard opening

P -40° F to +175° F (-40° C to +79° C) Step opening

R -40° F to +175° F (-40° C to +79° C) Standard opening—convertible (Natural/LP) for

Table 4. Thermostat Current (Run Mode).

Model 24 Vac, 50/60 Hz

SV9401/SV9402/SV9403 0.20A/0.20A

SV9501/SV9502/SV9503 0.20A/0.20A

SV9601/SV9602 0.20A/0.20A

Ignition Sequence Timing at 60 Hz Input

Prepurge Time (Factory-set on SV9402, SV9502, and

SV9602): 15 or 30 seconds depending on model.

Trial for Ignition:

90 seconds.

Automatic Reset Time:

5 minutes.

NOTE: The SV9403 and SV9503 are lockout models

and do not provide Automatic Reset Time.

Flame Failure Response Time:

mobile home operation.

1.6 seconds maximum at 3 µA.

IMPORTANT

All timings increase by 20 percent with 50 Hz input.

Gas Conversion Kits: See Table 5 for gas conversion

kit information.

NOTE: See appliance manufacturer specifications and

instructions and information in these installation instructions before attempting to convert an appliance.

Pipe Adapters: Angle and straight flange adapters

available for 3/8-, 1/2- and 3/4-in. NPT pipe. See

Table 6.

NOTE: Models with 3/4 in. inlet or outlet do not

accommodate the adapter kits.

Table 5. Available Gas Conversion Kits.

Model No. Suffix Letter Kit to Convert Natural Gas to LP Kit to Convert LP to Natural Gas

H, M 393691 394588

P Not field convertible Not field convertible

R Not required (convertible regulator) Not required (convertible regulator)

69-1004—2 2

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SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 SMARTVALVE™ SYSTEM CONTROLS

Table 6. Flange Adapter Part Numbers.

Inlet/Outlet Pipe

Size Flange Type

3/8 in. NPT Straight 393690-1 393690-11

Elbow 393690-2 393690-12

1/2 in. NPT Straight 393690-6 393690-16

Elbow 393690-3 393690-13

3/4 in. NPT Straight 393690-4 393690-14

Elbow 393690-5 393690-15

Flange kits include one flange, one O-ring, and four mounting screws.

Do not use flanges on control models with 3/4 in. inlet or outlet. On models with 1/2 inlet and 3/4 in. outlet, use flanges only on the 1/2 in. inlet side.

Approvals: International Approval Services (IAS):

Design Certified C2030017.

PLANNING THE INSTALLATION

WARNING

Fire or Explosion Hazard. Can cause severe injury, death or property damage.

Follow these warnings exactly:

1. Plan the installation as outlined below.

2. Plan for frequent maintenance as described in

When intermittent pilot systems are used on central heating equipment in barns, greenhouses, and commercial properties and on heating appliances such as commercial cookers, agricultural equipment, industrial heating equipment and pool heaters, heavy demands are made on the controls. Special steps may be required to prevent nuisance shutdowns and control failure due to frequent cycling, severe environmental conditions related to moisture, corrosive chemicals, dust or excessive heat. These applications require Honeywell Home and Building Control Engineering review; contact your Honeywell Sales Representative for assistance.

Review the following conditions that can apply to your specific installation and take the precautionary steps suggested.

Frequent Cycling

This control is designed for use on appliances that typically cycle three to four times an hour only during the heating season. In year-around applications and applications with greater cycling rates, the control can wear out more quickly. Perform a monthly checkout as described in this instruction manual.

Water or Steam Cleaning

If a control gets wet, replace it. If the appliance is likely to be cleaned with water or steam, protect (cover) the control and wiring from water or steam flow. Mount the control high enough above the bottom of the cabinet so it does not get wet during normal cleaning procedures.

the Maintenance section.

Without Hex Wrench With Hex Wrench

High Humidity or Dripping Water

Dripping water can cause the control to fail. Never install an appliance where water can drip on the control. In addition, high ambient humidity can cause the control to corrode and fail. If the appliance is in a humid atmosphere, make sure air circulation around the control is adequate to prevent condensation. Also, regularly check out the system as described in this instruction manual.

Corrosive Chemicals

Corrosive chemicals can attack the control, eventually causing a failure. If chemicals are used for routine cleaning, avoid contact with the control. Where chemicals are suspended in air, as in some industrial or agricultural applications, protect the control in an enclosure.

Dust or Grease Accumulation

Heavy accumulations of dust or grease can cause the control to malfunction. Where dust or grease can be a problem, provide covers for the control to limit contamination.

Heat

Excessively high temperatures can damage the control. Make sure the maximum ambient temperature at the control does not exceed the control rating. If the appliance operates at very high temperatures, use insulation, shielding, and air circulation, as necessary, to protect the control. The appliance manufacturer should provide proper insulation or shielding; verify proper air circulation is maintained when the appliance is installed.

INSTALLATION

When Installing this Product…

1. Read these instructions carefully. Failure to follow

2. Check the ratings given in the instructions and on

3. Installer must be a trained, experienced service

4. After installation is complete, check out product

Flange Kit Part No.

them could damage the product or cause a hazardous condition.

the product to make sure the product is suitable for your application.

technician.

operation as provided in these instructions.

a,b

3 69-1004—2

Page 43

SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 SMARTVALVE™ SYSTEM CONTROLS

WARNING

Fire or Explosion Hazard. Can cause severe injury, death or property damage.

Follow these warnings exactly:

1. Disconnect power supply before wiring to prevent electrical shock or equipment damage.

2. To avoid dangerous accumulation of fuel gas, turn off gas supply at the appliance service valve before starting installation, and perform Gas Leak Test after completion of installation.

3. Do not bend pilot tubing at ignition system control or pilot burner after compression fitting is tightened, or gas leakage at the connection can result.

4. Always install a sediment trap in gas supply line to prevent contamination of ignition system control.

WARNING

Electrical Shock or Equipment Damage Hazard. Can cause severe injury, death or equipment damage.

1. Never apply a jumper across or short the thermostat, 24V hot or 24V common terminal in the SV9401/SV9402/SV9403, SV9501/ SV9502/SV9503, or SV9601/SV9602 wiring harness. This can burn out the heat anticipator in the thermostat or damage the system transformer.

2. Never short the electronic fan timer (EFT) output. This can damage the EFT drive circuitry.

IMPORTANT

These ignition system controls are shipped with protective seals over the inlet and outlet tappings. Do not remove the seals until ready to connect the piping.

Follow the appliance manufacturer instructions if available; otherwise, use these instructions as a guide.

Converting Ignition System Control from Natural Gas to LP Gas Application (or LP Gas to Natural Gas Application)

WARNING

Fire or Explosion Hazard. Can cause severe injury, death or property damage.

1. Do NOT attempt to convert step-opening models (SV9401P/SV9402P/SV9403P, SV9501P/SV9502P/SV9503P, or SV9601P/ SV9602P).

2. Always change the main and pilot burner orifices when converting from natural to LP gas or from LP to natural gas. Follow appliance manufacturer specifications and instructions to assure proper appliance conversion.

3. Ignition system controls are factory-set for natural (and manufactured) or LP gas. Do not attempt to use an ignition system control set for natural (manufactured) gas on LP gas, or an ignition system control set for LP gas on natural (manufactured) gas.

Convertible (Natural/LP) Regulator for Mobile Home Applications

Ignition system controls with suffix letter R are convertible pressure regulator models. They can be converted from natural gas to LP or from LP to natural gas without a conversion kit.

Before converting the ignition control from one gas to another, check the ignition control label and the appliance manufacturer rating plate to determine if the factory-set pressure regulator setting meets the appliance manifold requirements after conversion.

NOTE: Convertible pressure regulator models (suffix

letter R) do not have field-adjustable regulators.

If the factory pressure regulator setting meets the appliance manifold requirement, convert the ignition control using the following procedure:

1. Remove the pressure regulator cap. See Fig.

2. Turn over the cap so the letters facing up are for

the gas type the appliance uses NAT for natural gas and LP for LP gas.

3. Replace the cap and tighten firmly.

69-1004—2 4

Install Adapters on Control

IMPORTANT

3/4 in. inlets and outlets do not accommodate flange adapters.

If adapters are being installed on the control, mount them as follows:

Flanges

1. 1.Choose the appropriate flange for your application as listed in Table 5.

2. 2.Remove the seal over the ignition system control inlet or outlet.

Page 44

SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 SMARTVALVE™ SYSTEM CONTROLS

P R C

the installation includes the adapters and screws. If you

RESSURE EGULATOR AP

OTHER SID OF CAP

M1167

Fig. 1. Convertible Regulator for SmartValves.

3. Make sure that the O-ring fits in the groove of the

flange. If the O-ring is not attached or missing, do not use the flange.

4. With the O-ring facing the ignition system control, align the screw holes on the ignition system control with the holes in the flange. Insert and tighten the screws provided with the flange. See Fig. 2. Tighten the screws to 25 inch-pounds of torque to provide a gas-tight seal.

use a wrench on the valve after the flanges are installed, use the wrench only on the flange, not on the control. See Fig. 6.

Location

The SV9401/SV9402/SV9403, SV9501/SV9502/ SV9503, and SV9601/SV9602 are mounted in the appliance vestibule on the gas manifold.

IMPORTANT

Make sure the mounting location protects the control from dripping water and excessive humidity.

IMPORTANT

Make sure the mounting location maximum and minimum ambient temperature are both within the specified acceptable range.

Install Piping on Control

All piping must comply with local codes and ordinances or with the National Fuel Gas Code (ANSI Z223.1 NFPA No. 54), as applicable.

1. Use new, properly reamed pipe free from chips. If tubing is used, make sure the ends are square, deburred and clean. All tubing bends must be smooth and without deformation.

2. Run pipe or tubing to the ignition system control. If tubing is used, obtain a tube-to-pipe coupling to connect the tubing to the ignition system control.

3. Install a sediment trap in the supply line to the ignition system control as shown in Fig. 3.

VALVE OUTLET

DO NOT USE FLANGES ON 3/4 IN. INLET AND 3/4 IN. OUTLET

MODELS, AND ON THE 3/4 IN. OUTLET SIDE OF 1/2 IN. INLET AND 3/4 IN. OUTLET MODELS.

Fig. 2. Firmly fasten flange to valve but do not

FLANGE

9/64 INCH HEX SCREWS (4)

overtighten screws.

Bushings

1. Remove the seal over the ignition system control inlet or outlet.

2. Apply a moderate amount of good quality pipe compound to the bushing, leaving two end threads bare. On an LP installation, use compound resistant to LP gas. Do not use Teflon tape.

3. Insert the bushing in the ignition system control and carefully thread the pipe into the bushing until tight.

Follow the instructions below to installing the piping, and control. Connect the pilot tubing and wiring. Make sure the leak test you perform on the control after completing

DROP

PIPED GAS SUPPLY

IGNITION SYSTEM CONTROL

DROP

TUBING

GAS SUPPLY

IGNITION SYSTEM CONTROL

M7927C

HORIZONTAL

3 IN. (76 MM) MINIMUM

HORIZONTAL

RISER

3 IN. (76 MM) MINIMUM

ALL BENDS IN METALLIC TUBING MUST BE SMOOTH.

CAUTION

Gas Leakage Hazard. Failure to follow precautions can result in a gas-filled work area. Shut off the main gas supply before removing end cap. Test for gas leakage when installation is complete.

Fig. 3. Sediment trap installation.

5 69-1004—2

RISER

PIPED GAS SUPPLY

3 IN. (76 MM) MINIMUM

IGNITION SYSTEM CONTROL

M3343C

Page 45

SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 SMARTVALVE™ SYSTEM CONTROLS

T S I

Install Control

1. This ignition system control can be mounted 0 to 90 degrees in any direction, including vertically, from the upright position of the ignition system control switch.

2. Mount the control so the gas flow is in the direction of the arrow on the bottom of the ignition system control.

3. Thread the pipe the amount shown in Table 7 for maximum pipe insertion into ignition system control or adapters. Do not thread pipe too far. Valve distortion or malfunction can result if the pipe is inserted too deeply.

4. Apply a moderate amount of good quality pipe compound (do not use Teflon tape) only to the pipe, leaving two end threads bare as shown in Fig. 4. On LP installations, use a compound resistant to LP gas.

Table 7. NPT Pipe Thread Length (in.).

Pipe

Thread Pipe

Size

(Inches)

this Amount

(Inches)

3/8 9/16 3/8

1/2 3/4 1/2

3/4 13/16 3/4

5. Remove the seals over the ignition system control inlet and outlet, if necessary.

6. Connect the pipe to the ignition system control inlet and outlet. Use a wrench on the square ends of the ignition system control. If a flange is used, place the wrench on the flange rather than on the ignition system control as shown in Fig. 5 and 6.

Maximum Depth Pipe Can

be Inserted into Control

(Inches)

TWO IMPERFECT THREADS

HREAD PIPE THE AMOUNT HOWN IN TABLE FOR INSERTION

NTO IGNITION SYSTEM CONTROL

IGNITION SYSTEM CONTROL

PIPE

APPLY A MODERATE AMOUNT OF PIPE COMPOUND ONLY TO PIPE (LEAVE TWO END THREADS BARE

Fig. 4. Use moderate amount of pipe compound.

Connect Pilot Gas Tubing

1. Cut tubing to the desired length and bend as necessary for routing to the pilot burner. Do not make sharp bends or deform the tubing. Do not bend the tubing at the ignition system control after the compression nut is tightened because this can result in gas leakage at the connection.

2. Square off and remove burrs from the end of the tubing.

3. Unscrew the brass compression fitting from the pilot outlet as shown in Fig. 6.

4. Slip the fitting over the tubing and slide out of the way as shown in Fig. 7.

5. Push the tubing into the pilot gas tapping on the outlet end of the control until it bottoms.

6. While holding the tubing all the way in, slide the fitting into place and engage the threads; then turn until finger tight.

7. Then tighten one more turn with a wrench. Do not overtighten.

8. Connect the other end of the tubing to the pilot burner according to the instructions supplied with Q3450/Q3480.

NOTE: The pilot tubing provides the SmartValve™

System flame sense current path. Make sure the connections are clean and tight for proper appliance operation.

M334

WHEN FLANGE IS NOT USED

PPLY WRENCH FROM TOP OR BOTTOM OF IGNITION SYSTEM CONTROL TO EITHER SHADED AREA

Fig. 5. Proper use of wrench on ignition system control with and without flanges.

69-1004—2 6

WHEN FLANGE IS USED

APPLY WRENCH TO FLANGE ONLY

M7928

Page 46

SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 SMARTVALVE™ SYSTEM CONTROLS

system power review is recommended. Install a

PRESSURE REGULATOR ADJUSTMENT (UNDER CAP SCREW)

INLET PRESSURE TAP

OFF

CONTROL

CONTROLS CONNECTOR

IGNITER

INLET

IGNITION SYSTEM CONTROL SWITCH

M7934

Fig. 6. Top view of ignition system control.

IGNITER CONNECTOR

OUTLET

PRESSURE

TAP

OUTLET

PILOT OUTLET

PILOT ADJUSTMENT

(UNDER CAP SCREW)

transformer, thermostat and other controls, as required.

2. Connect control circuit to the ignition system control using the keyed plug connector. See Fig. 8 through 11.

IGNITION SYSTEM CONTROL

TIGHTEN NUT ONE TURN BEYOND FINGER TIGHT

FITTING BREAKS OFF AND CLINCHES TUBING AS NUT IS TIGHTENED

Fig. 7. Always use new compression fitting.

TO PILO BURNER

M334

Wiring

Follow the wiring instructions furnished by the appliance manufacturer if available. Otherwise, use these instructions. Where these instructions differ from the appliance manufacturer, follow the appliance manufacturer instructions.

IMPORTANT

All wiring must comply with applicable electrical

WARNING

Electrical Shock Hazard or Equipment Damage Hazard Can cause severe injury, death or equipment damage.

Disconnect power supply before making wiring connections.

1. Check the power supply rating on the ignition system control and make sure it matches the available supply. The system transformer should be NEMA rated for 40 VA or higher. An appliance

120/240 VAC

PILOT BURNER GROUND (THROUGH PILOT TUBING)

24 VOLT COMMON

24 VOLT HOT

EFT OUTPUT

24 VOLT THERMOSTAT OR PRESSURE SWITCH

POWER SUPPLY. PROVIDE

DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

Fig. 8. SV9401/SV9402/SV9403, SV9501/SV9502/

SV9503, SV9601/SV9602 basic wiring diagram.

PILOT BURNER GROUND (THROUGH PILOT TUBING)

POWER SUPPLY

NEMA 40 VA TRANSFORMER

24 VAC

THERMOSTAT

TO ELECTRONIC FAN TIMER (IF USED)

LIMIT

M7935C

7 69-1004—2

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SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 SMARTVALVE™ SYSTEM CONTROLS

FUSE

HUMIDIFIER

AIR CLEANER

INDUCER MOTOR

UNUSED

3 DI

EAC N

HUM N

STARTING CAP

2 LO ML

CIRCULATING FAN

THERMOSTAT

CONNECT ONLY IF CONTINUOUS SPEED IS AVAILABLE AND USED.

CONNECT ONLY IF CONTINUOUS SPEED IS NOT USED.

CONNECT IF EAC AND HUM TERMINALS ARE AVAILABLE AND USED.

SOME MODELS USE MALE 1/4-INCH QUICK-CONNECTS INSTEAD

OF SCREW TERMINALS FOR THERMOSTAT CONNECTIONS.

Fig. 9. SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 typical wiring connections in fan

1 2

DELAY

SPEED

OFF

assisted warm air furnace with electronic fan timer.

MOTOR

C Y

LEADS

ST9120

NEUTRAL

CIR

L1(H)

L2(N)

CONT

TO 115/230 VAC POWER SUPPLY

BLWR

COOL

HEAT

115/230 VAC

24 VAC

SEC

XFMR

NOTE:

ROLL-OUT SWITCH

TRANSFORMER

CONTROL

COOLING CONTACTOR

= DENOTES STANDARD TERMINAL.

= DENOTES OPTIONAL TERMINAL.

DENOTES LOW VOLTAGE WIRING.

DENOTES LINE VOLTAGE WIRING.

LIMIT

PRESSURE SWITCH

PILOT BURNER GROUND (THROUGH PILOT TUBING)

24 VOLT COMMON

24 VOLT HOT

EFT OUTPUT

24 VOLT THERMOSTAT OR PRESSURE SWITCH

M7937D

D892

VENT DAMPER

4 3 2 1

BLACK

M7936C

Fig. 10. SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 typical wiring diagram in

RED

BLACK

COIL

CABLE AND CONNECTOR TO SUIT

AQUASTAT CONTROL

ROLLOUT SWITCH

SPILL SWITCH

THERMOSTAT

RED

CIRCULATOR PUMP

atmospheric boiler.

PILOT BURNER GROUND (THROUGH PILOT TUBING)

R8285D

BLACK

120 VAC POWER SUPPLY

POWER SUPPLY. PROVIDE

DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

69-1004—2 8

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SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 SMARTVALVE™ SYSTEM CONTROLS

COMBUSTION AIR BLOWER

R8222U RELAY

24V THERMOSTAT

L1 (HOT)

CIRCULATOR

POWER SUPPLY. PROVIDE DISCOUNNECT MEANS AND OVERLOAD

PROTECTION AS REQUIRED.

R8285D CONTROL CENTER

LIMIT

ROLL-OUT SWITCH

PILOT BURNER GROUND (THROUGH PILOT TUBING)

24 VOLT COMMON

24 VOLT THERMOSTAT OR PRESSURE SWITCH

24 VOLT HOT

EFT OUTPUT

Fig. 11. SV9402, SV9502, SV9602 typical wiring connections in induced draft boiler application.

PRESSURE

SWITCH

M13036B

STARTUP AND CHECKOUT

Ignition System Control Switch Settings

Ignition system control switch settings are:

OFF—Prevents pilot and main gas flow through the ignition system control.

ON—Permits gas to flow into the control body. Under control of the thermostat, gas can flow to the pilot and main burners.

NOTE: Controls are shipped with the ignition system

control switch in the ON position.

Turn on Main Burner

Follow the instructions provided by the appliance manufacturer or turn up the thermostat to call for heat.

Perform Gas Leak Test

WARNING

Fire or Explosion Hazard. Can cause severe injury, death or property damage.

Check for gas leaks with soap and water solution any time work is done on a gas system.

CAUTION

Equipment Damage Hazard. Liquids will damage the gas control.

Contact with soap and water can damage the control. Do not spray soap and water solution on the SmartValve housing.

Gas Leak Test

1. Paint pipe connections upstream of the ignition system control with rich s oap and water solution. Bubbles indicate a gas leak.

2. If a leak is detected, tighten the pipe connections.

3. Stand clear of the main burner while lighting to

prevent injury caused from hidden leaks that could cause flashback in the appliance vestibule. Light the main burner.

9 69-1004—2

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SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 SMARTVALVE™ SYSTEM CONTROLS

)

4. With the main burner in operation, paint the pipe joints (including adapters) and the control inlet and outlet with rich soap and water solution.

5. If another leak is detected, tighten the adapter screws, joints, and pipe connections.

6. Replace the part if a leak cannot be stopped.

Check and Adjust Pilot Flame

The pilot flame should envelop 3/8 to 1/2 in. (10 to 13 mm) of the tip of the flame rod. It should also be in continual contact with the ground electrode. See Fig. 12. If the pilot flame is small or lazy, or does not touch the ground electrode, the inlet gas pressure may be to low, or the pilot orifice may be partially clogged. Check and repair as necessary. If the pilot flame is hard and noisy, the inlet gas pressure may be too high. The ignition system control has a pilot adjustment mechanism to reduce the pilot flow, if necessary. Use the following procedure:

1. 1.Remove pilot adjustment cover screw. See Fig.

NOTE: Pilot adjustment is shipped at full flow rate.

2. Turn the inner adjustment screw clockwise if the inlet pressure is too high.

NOTE: If the adjustment screw is used to reduce pilot

flow rate, the pilot flame can become too small for reliable system operation if the system inlet pressure drops significantly.

3. Replace the cover screw after the adjustment to prevent gas leakage.

3/8 TO 1/2 IN

PROPER FLAME ADJUSTMENT

(10 TO 13 MM

Checking Gas Input by Clocking Gas Meter

IMPORTANT

1. Make sure there is no gas flow through the meter except to the appliance being checked. Other appliances must remain off with their pilot lights extinguished. Otherwise, subtract that usage from the meter reading.

2. Convert the flow rate to Btuh as described in Gas Controls Handbook, form 70-2602.1.Make sure there is no gas flow through the meter except to the appliance being checked. Other appliances must remain off with their pilot lights extinguished. Otherwise, subtract that usage from the meter reading.

3. Compare actual Btuh to the input rate on the appliance nameplate.

Checking Gas Input with Manometer

IMPORTANT

1. Make sure the ignition system control is in the OFF position before removing outlet pressure tap plug to connect manometer (pressure gauge).

2. Shut off gas supply at the manual valve in the gas piping to the appliance or, for LP, at the tank.

3. Move the ignition system control switch to the OFF position when removing the gauge and replacing the plug.

4. Remove inlet pressure tap plug.

5. Shut off gas supply.

6. Disconnect manometer and replace plug.

7. Repeat Gas Leak Test at plug with main burner operating.

NOTE: Check the inlet pressure before adjusting the

pressure regulator.

GROUND ELECTROD

FLAME ROD

HOT SURFAC

NOTE: GROUND ELECTRODE MUST NOT TOUCH FLAME ROD (.050 IN. MINIMUM CLEARANCE). BEND GROUND ELECTRODE IF NECESSARY. DO NOT BEND FLAME ROD

IGNITER

M3350A

Fig. 12. Proper flame adjustment.

Check and Adjust Gas Input and Burner Ignition

IMPORTANT

1. Do not exceed input rating stamped on the appliance nameplate.

2. Do not exceed manufacturers recommended burner orifice.

3. Make certain primary air supply to main burner is adjusted properly for complete combustion.

4. Follow appliance manufacturer instructions.

69-1004—2 10

Standard (M) and Slow-Opening (H) Pressure Regulator Models

1. Carefully check the main burner lightoff to make sure the burner lights smoothly and all the ports remain lit.

2. Check the full rate manifold pressure listed on the appliance nameplate. The ignition system control full rate outlet pressure should match this rating.

3. With the main burner operating, check the ignition system control flow using the meter clocking method or check pressure using a manometer connected to the output pressure tap on the ignition system control.

4. Adjust the pressure regulator (if necessary) to match the appliance rating. See Tables 8 and 9 for factory set nominal outlet pressure and adjustment range. a. Remove the pressure regulator adjustment cap

screw.

b. Using a screwdriver, turn the inner adjustment

screw clockwise to increase or counterclockwise to decrease the gas pressure to the burner.

c. Replace the cap screw and tighten firmly to

prevent gas leakage.

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SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 SMARTVALVE™ SYSTEM CONTROLS

5. If the desired outlet pressure or flow rate cannot be achieved by adjusting the ignition system control, check the ignition system control inlet pressure using a manometer at the inlet pressure tap of the ignition system control. If the inlet pressure is in the nominal range (Tables 8A and 8B), replace the ignition system control. Otherwise, take the necessary steps to provide proper gas pressure to the control.

NOTE: If the burner firing rate is above 85,000 Btuh on

SV9401/SV9402/SV9403 or 150,000 Btuh for SV9501/SV9502/SV9503 models (see Table 2 for SV9601/SV9602 capacities), it may not be possible to deliver the desired outlet pressure. This is an application issue, not a control failure. Take whatever steps are required to correct the situation.

Step-Opening (P) Pressure Regulator Models

Step-opening models require you to check and adjust the full-rate pressure first and then check the step pressure. The step pressure is not field-adjustable.

1. Carefully check the main burner lightoff to make sure the burner lights smoothly and all the ports remain lit.

2. Check the manifold pressure listed on the appliance nameplate. The ignition system control full rate outlet pressure should match this rating.

Table 8. Pressure Regulator Specification Pressures (in. wc).

Nominal Inlet

Model Type Type of Gas

Standard Slow NAT 5.0 - 7.0 — 3.5 — 3 - 5

LP 12.0 - 14.0 — 10.0 — 8 - 12

Step NAT 5.0 - 7.0 0.9 3.5 None 3 - 5

LP 12.0 - 14.0 2.2 10.0 None 8 - 12

Convertible NAT 5.0 - 7.0 — 3.5 None None

LP 12.0 - 14.0 — 10.0 None None

Pressure

Range

4. Adjust the pressure regulator (if necessary) to

match the appliance rating. See Tables 8 and 9 for factory set nominal outlet pressure and adjustment range. a. Remove the pressure regulator adjustment cap

screw.

b. Using a screwdriver, turn the inner adjustment

screw clockwise to increase or counterclockwise to decrease the gas pressure to the burner.

c. Replace the cap screw and tighten firmly to

prevent gas leakage.

6. Carefully check the burner lightoff at step pressure to make sure the burner lights smoothly, without flashback to the orifice. Make sure all ports remain lit.

7. Cycle the burner several times, allowing at least 60 seconds between cycles for the regulator to resume the step function.

8. Repeat steps 6 and 7 after allowing the burner to cool.

9. Readjust the full rate outlet pressure (if necessary) to improve lightoff characteristics.

Convertible (R) Models

Models with convertible (NAT/LP) regulators, used for mobile home applications, are not field-adjustable. Do not attempt to adjust outlet pressure on these controls. Use the instructions in this manual for changing between LP and natural gas.

Factory Set Nominal Outlet

Pressure Setting Range

Step Full Rate Step Full Rate

Table 9. Pressure Regulator Specification Pressures (kPa).

Nominal Inlet

Model Type Type of Gas

Standard Slow NAT 1.2 - 1.7 — 0.9 — 0.7 - 1.2

LP 2.9 - 3.9 — 2.5 — 2.0 - 3.0

Step NAT 1.2 - 1.7 0.2 0.9 None 0.7 - 1.2

LP 2.90 - 3.9 0.5 2,5 None 2.0 - 3.0

Convertible NAT 1.2 - 1.7 — 0.9 None None

LP 2.9 - 3.9 — 2.5 None None

Pressure

Range

Factory Set Nominal Outlet

Pressure Setting Range

Step Full Rate Step Full Rate

11 69-1004—2

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SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 SMARTVALVE™ SYSTEM CONTROLS

MAINTENANCE

WARNING

Fire or Explosion Hazard. Can cause severe injury, death or property damage.

Do not attempt to take the control apart or clean it. Improper cleaning or reassembly can cause gas leakage.

Regular preventive maintenance is important in applications such as in the commercial cooking and agricultural and industrial industries that place a heavy load on system controls because:

• In many such applications, particularly commercial cooking, the equipment operates 100,000 to 200,000 cycles per year. Such heavy cycling can wear out the gas control in one to two years.

• Exposure to water, dirt, chemicals and heat can damage the gas control and shut down the control system.

The maintenance program should include regular checkout of the control as outlined in the Startup and Checkout section, and the control system as described in the appliance manufacturer literature.

Maintenance frequency must be determined individually for each application. Some considerations are:

• Cycling frequency. Appliances that may cycle 20,000 times annually should be checked monthly.

• Intermittent use. Appliances that are used seasonally should be checked before shutdown and again before the next use.

• Consequence of unexpected shutdown. Where the cost of an unexpected shutdown would be high, the system should be checked more often.

• Dusty, wet, or corrosive environment. Because these environments can cause the gas control to deteriorate more rapidly, the system should be checked more often.

The system should be replaced if:

• It does not perform properly on checkout or troubleshooting.

• The gas control is likely to have operated for more than 200,000 cycles.

• The control is wet or looks as if it has been wet.

SERVICE

CAUTION

Equipment Damage Hazard. Disassembly can cause equipment damage.

Do not disassemble the ignition system control; it contains no replaceable components. Attempted disassembly or repair can damage the ignition system control.

CAUTION

Electrical Equipment Damage Hazard. Incorrect wiring can cause equipment damage.

Do not apply a jumper across or short the thermostat, 24V hot or 24V common terminal in the SV9401/SV9402/SV9403, SV9501/SV9502/ SV9503, or SV9601/SV9602 wiring harness. This can burn out the heat anticipator in the thermostat or damage the system transformer.

Carefully read the Sequence of Operation and Troubleshooting information before attempting to service the appliance. After servicing, make sure the system operates properly.

IMPORTANT

Allow 60 seconds after shutdown before reenergizing a step-opening model to assure lightoff at step pressure.

SEQUENCE OF OPERATION

Fig. 13 shows the sequence of operation for this family of gas controls. When reviewing sequence of operation:

• Make sure the appliance is powered with the gas supply turned on.

• Make sure the ignition system control switch is in the ON position.

TROUBLESHOOTING

If Main Burner Will Not Come On With Call for Heat

1. Make sure the appliance has power and the gas supply is turned on.

2. Make sure the ignition system control switch is in the ON position.

3. Adjust the thermostat several degrees above room temperature.

4. If the appliance does not light, check for proper ignition control system operation. Use Fig. 13.

5. If it appears the ignition control system is not working properly, use Fig. 14 as a troubleshooting guide.

IMPORTANT

1. Proper troubleshooting requires measurement

of voltage and resistance with a volt/ohm meter.

2. Use proper size probes and appropriate testing

techniques to get good test information without damaging the control terminals, connectors, or wiring harness.

Use the following basic troubleshooting procedure:

1. Review this information carefully before going to the job site.

2. Identify the specific ignition control model on the appliance.

3. Make sure the Q3450/Q3480 HSI element is good.

4. Make sure the ignition control switch (knob if

SV9500) is in the ON position unless directed otherwise in the Troubleshooting flow chart.

69-1004—2 12

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SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 SMARTVALVE™ SYSTEM CONTROLS

P S C

START

REPURGE/ YSTEM HECK

TRIAL FOR IGNITION

MAIN BURNER OPERATION

END

APPLY 24 V A C TO APPLIANCE

THERMOSTAT CALLS FOR HEAT

PREPURGE (SV9X02 ONLY)

YES

FLAME SIGNAL DETECTED?

INTERNAL CHECK OKAY?

• PILOT VALVE OPENS

• IGNITER POWERED

PILOT LIGHTS AND FLAME IS SENSED DURING TRIAL FOR IGNITION?

• IGNITER OFF

• MAIN VALVE OPENS

ELECTRONIC FAN TIMER (EFT) OUTPUT ENERGIZES

FLAME SIGNAL LOST?

THERMOSTAT CALL FOR HEAT ENDS

• MAIN AND PILOT VALVES CLOSE

• EFT OUTPUT DE-ENERGIZES

IGNITER WILL TURN OFF ABOUT 30 SECONDS INTO THE TRIAL FOR IGNITION IF THE PILOT FLAME HAS NOT LIT. IT WILL TURN BACK

ON FOR THE FINAL 30 SECONDS OF THE 90 SECOND TRIAL FOR IGNITION. THE PILOT VALVE WILL BE ENERGIZED DURING THE ENTIRE TRIAL FOR IGNITION. THIS IS NORMAL OPERATION FOR THIS GAS IGNITION SYSTEM.

YES

• WAIT FOR FLAME SIGNAL TO DISAPPEAR.

• PILOT VALVE/IGNITER REMAIN OFF

• PILOT VALVE CLOSES

• IGNITER OFF SV9X03

LOCKOUT

YES

• MAIN AND PILOT VALVES CLOSE

• EFT OUTPUT DE-ENERGIZES

FLAME LOST MORE THAN FIVE TIMES IN ONE CALL FOR HEAT?

YES SV9X01, SV9X02

THREE-SECOND FLAME FAILURE RECYCLE DELAY

SV9X01, SV9X02

YES SV9X03

Fig. 13. SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 SmartValve sequence of operation.

SV9X01/SV9X02/SV9X03 SmartValve™ FAMILY SEQUENCE OF OPERATION

5. Make sure the appliance call for heat function provides proper inputs to the ignition control through the 2X2 power connector.

6. Follow the Operating Sequence and Troubleshooting flow charts Fig. 13 and Fig. 14 to determine if the ignition control system is defective.

NOTE: Most modern gas appliances have more than

one component in the control string. Improper operation of any one component in the control string can cause the appliance to fail to operate. Use Fig. 14 to locate and correct the true source of the problem.

FIVE-MINUTE RETRY DELAY

M17218

13 69-1004—2

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SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 SMARTVALVE™ SYSTEM CONTROLS

V9X01/SV9X02/SV9X03 SmartValve™ TROUBLESHOOTING SEQUENCE

NOTE: BEFORE TROUBLESHOOTING,

START

• TURN OFF GAS SUPPLY

• ASSURE SmartValve SWITCH IS IN ON POSITION

• DISCONNECT SYSTEM CONTROL HARNESS

• SET THERMOSTAT TO CALL FOR HEAT

CHECK FOR PROPER VOLTAGE AT CONTROL HARNESS (SEE INSET A). VOLTAGE SHOULD BE 24V BETWEEN THERMOSTAT OR PRESSURE SWITCH AND 24V COMMON, AND 24V BETWEEN 24V COMMON AND 24V HOT.

PLUG HARNESS INTO SmartValve CONTROL. WAIT FOR INTERNAL CHECK DELAY (SV9X01, SV9X03) OR PREPURGE (SV9X02)

IGNITER WARMS UP AND GLOWS RED

• TURN ON GAS SUPPLY

• PILOT BURNER LIGHTS

YES

MAIN VALVE OPENS AND MAIN BURNER LIGHTS

YES

BECOME FAMILIAR WITH THE STARTUP AND CHECKOUT PROCEDURE. ALSO CHECK PILOT BURNER ELEMENT FOR RESISTANCE LESS THAN 10 OHMS WITH ELEMENT AT ROOM TEMPERATURE.

CHECK:

• LINE VOLTAGE POWER

• LOW VOLTAGE TRANSFORMER

• LIMIT CONTROLLER

• THERMOSTAT

• WIRING

• AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM

• VENT DAMPER (IF USED) IS OPEN AND END SWITCH MAKES

WITH PILOT BURNER CABLE CONNECTED, MEASURE

VOLTAGE AT SmartValve HSI ELEMENT OUTPUT (SEE INSET B) 24V NOMINAL.

REPLACE IGNITER/FLAME ROD ASSEMBLY

CHECK THAT PILOT GAS IS FLOWING. WAIT TO ASSURE PILOT GAS TUBING IS PURGED. RECYCLE CALL FOR HEAT IF NECESSARY.

MEASURE VOLTAGE BETWEEN 24V HOT AND 24V COMMON LEADS TO SmartValve CONTROL. MUST MEASURE AT LEAST 19.5 VAC WITH IGNITER POWERED. SEE INSET A TO IDENTIFY PROPER LEAD. THIS CHECK MUST BE DONE WITH THE SmartValve CONTROL CONNECTED AND IGNITER POWERED.

REPLACE IGNITER/FLAME ROD ASSEMBLY

• CHECK THAT PILOT FLAME MAKES GOOD CONTACT WITH PILOT BURNER FLAME ROD.

• ASSURE PILOT MOUNTING BRACKETS AND PILOT BURNER ARE NOT BENT OR DAMAGED.

• CHECK GAS SUPPLY PRESSURE.

• CHECK PILOT BURNER ORIFICES FOR CONTAMINATION OR DAMAGE

• CHECK FOR GOOD ELECTRICAL CONNECTION THROUGH THE PILOT TUBING.

• IF ALL OF THE ABOVE ARE GOOD, REPLACE IGNITER/FLAME ROD ASSEMBLY

YES

INSET A

24 VOLT THERMOSTAT OR PRESSURE SWITCH

24 VOLT COMMON

CHECK FOR DAMAGED OR MISSING TERMINALS IN CONNECTOR

INSET B

REPLACE SmartValve CONTROL

CHECK TRANSFORMER AND LINE VOLT SUPPLY

HSI TERMINALS

END VIEW OF CONTROL HARNESS CONNECTOR

EFT OUTPUT

24 VOLT HOT

CYCLE THERMOSTAT OFF AND BACK ON

SYSTEM IS OKAY

IGNITER WILL CYCLE OFF AND BACK ON ONCE DURING THE 90 SECOND IGNITION TRIAL. ALL VOLTAGE MEASUREMENTS MUST BE TAKEN WHILE THE IGNITER IS POWERED.

Fig. 14. SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 SmartValve troubleshooting

MAIN BURNER LIGHTS

WHEN MEASURING VOLTAGE AT CONNECTIONS, USE

CARE TO ASSURE TERMINALS ARE NOT DAMAGED.

sequence.

REPLACE SmartValve CONTROL

69-1004—2 14

M17217

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SV9401/SV9402/SV9403, SV9501/SV9502/SV9503, SV9601/SV9602 SMARTVALVE™ SYSTEM CONTROLS

INSTRUCTIONS TO THE HOMEOWNER

WARNING

Fire or Explosion Hazard. Can cause severe injury, death or property damage.

Follow these warnings exactly:

1. Do not light the pilot flame manually.

2. Before lighting the pilot burner flame, smell around the appliance for gas. Be sure to smell next to the floor because LP gas is heavier than air.

WARNING

Fire or Explosion Hazard. Can cause severe injury, death or property damage.

If you smell gas:

1. Turn off the gas supply at the appliance service

valve. On LP gas systems, turn off the gas supply at the gas tank.

2. Do not light any appliances in the house.

3. Do not touch electrical switches or use the

phone.

4. Leave the building and use a neighbor ’s phone

to call your gas supplier.

5. If you cannot reach your gas supplier, call the

fire department.

The ignition system control must be replaced in event of any physical damage, tampering, bent terminals, missing or broken parts, stripped threads, or evidence of exposure to heat, water, or excessive moisture.

IMPORTANT

Follow the operating instructions provided by the manufacturer of your heating appliance. These instructions describe a typical ignition system control application, but the specific controls used and the procedures outlined by the manufacturer of your appliance can differ, requiring special instructions.

STOP: Read the Warnings Above.

The pilot flame is lit automatically. If the appliance does not turn on when the thermostat is set several degrees above room temperature, follow these instructions:

1. Set the thermostat to its lowest setting to reset the safety control.

2. Disconnect all electric power to the appliance.

3. Remove the ignition system control access panel.

4. Move the ignition system control switch to the OFF

position.

5. Wait five minutes to clear out any unburned gas. If you then smell gas, STOP! Follow the Warnings above. If you do not smell gas, continue with the next step.

6. Move the ignition system control switch to the ON position.

7. Replace the ignition system control access panel.

8. Reconnect all electric power to the appliance.

9. Set the thermostat to the desired setting.

10. If the appliance does not turn on, move the ignition

system control switch to the OFF position and contact a qualified service technician for assistance.

TURNING OFF THE APPLIANCE

Vacation Shutdown—

Set the thermostat to the desired room temperature while you are away.

Complete Shutdown—

Turn off power to the appliance. Turn off the gas supply to the appliance. Appliance will completely shut off. Follow the procedure in the Instructions to the Homeowner section above to resume normal operation.

15 69-1004—2

Page 55

Automation and Control Solutions

Honeywell International Inc. Honeywell Limited-Honeywell Limitée 1985 Douglas Drive North 35 Dynamic Drive Golden Valley, MN 55422 Scarborough, Ontario

69-1004—2 D.A. Rev. 03-99 www.honeywell.com

M1V 4Z9

Printed in U.S.A. on recycled paper containing at least 10% post-consumer paper fibers.

Page 56

P.O. Box 80400, Simpsonville, S.C. 29680-0400, USA http://www.bkideas.com

Made and printed in the U.S.A LI0101/0205

BKI SV9403 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual