Page 1
24G Series Flatbottom Gas Fryers (CE)
Installation & Operation Manual
Models 1824 & 2424G
CE ONLY
*8195705*
Service Hotline 1-318-865-1711
Price: $10.00
819-5705
JUNE 2002
Page 2
Please read all sections of this manual and retain for future reference.
NOTICE
This appliance is intended for professional use only and is to be operated by qualified
personnel only. A Dean Factory Authorized Service Center (FASC) or other qualified
professional should perform installation, maintenance, and repairs. Installation, maintenance,
or repairs by unqualified personnel may void the manufacturer’s warranty. See Chapter 1 of
this manual for definitions of qualified personnel.
NOTICE
This equipment must be installed in accordance with the appropriate national and local codes of
the country and/or region in which the appliance is installed.
NOTICE
Drawings and photos used in this manual are intended to illustrate operational, cleaning and
technical procedures and may not conform to onsite management operational procedures.
NOTICE TO OWNERS OF UNITS EQUIPPED WITH COMPUTERS
U.S.
This device complies with Part 15 of the FCC rules. Operation is subject to the following two
conditions: 1) This device may not cause harmful interference, and 2) This device must accept
any interference received, including interference that may cause undesired operation. While
this device is a verified Class A device, it has been shown to meet Class B limits.
Canada
This digital apparatus does not exceed the Class A or B limits for radio noise emissions as set
out by the ICES-003 standard of the Canadian Department of Communications.
Cet appareil numerique n’emet pas de bruits radioelectriques depassany les limites de classe A
et B prescrites dans la norme NMB-003 edictee par le Ministre des Communications du Canada.
DANGER
Improper installation, adjustment, maintenance or service, and unauthorized alterations or
modifications can cause property damage, injury, or death. Read the installation, operating and
service instructions thoroughly before installing or servicing this equipment. Only qualified
service personnel may convert this appliance to use a gas other than that for which it was
originally configured. See Chapter 1 of this manual for definition of qualified service personnel.
DANGER
Adequate means must be provided to limit the movement of this appliance without depending
upon the gas line connection. Single fryers equipped with legs must be stabilized by installing
anchor straps. All fryers equipped with casters must be stabilized by installing restraining
chains. If a flexible gas line is used, an additional restraining cable must be connected at all
times when the fryer is in use.
Page 3
DANGER
The front ledge of the fryer is not a step. Do not stand on the fryer. Serious injury can result
from slips or contact with the hot oil.
DANGER
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any
other appliance.
DANGER
Instructions to be followed in the event the operator smells gas or otherwise detects a gas leak
must be posted in a prominent location. This information can be obtained from the local gas
company or gas supplier.
DANGER
The crumb tray in fryers equipped with a filter system must be emptied into a fireproof container
at the end of frying operations each day. Some food particles can spontaneously combust if left
soaking in certain shortening material. Additional information can be obtained in the filtration
manual included with the system.
WARNING
No structural material on the fryer should be altered or removed to accommodate placement of
the fryer under a hood. Questions? Call the Dean Service Hotline at 1-800-551-8633.
WARNING
Do not bang fry baskets or other utensils on the fryer’s joiner strip. The strip is present to seal
the joint between the frypot. Banging fry baskets on the strip to dislodge shortening will distort
the strip, adversely affecting its fit. It is designed for a tight fit and should only be removed for
cleaning.
IMPORTANT
Safe and satisfactory operation of Dean equipment depends upon its proper installation.
Installation MUST conform with local codes, or in the absence of local codes, to European
Community (CE) Standards.
NOTICE
The Commonwealth of Massachusetts requires any and all gas products to be installed by a
licensed plumber or pipe fitter.
Page 4
24G Series Flatbottom Gas Fryers (CE)
Installation & Operation Manual
TABLE OF CONTENTS
Page #
1. INTRODUCTION 1-1
1.1 Applicability and Validity 1-1
1.2 Ordering Parts 1-1
1.3 Service Information 1-1
1.4 Safety Information 1-2
1.5 Service Personnel 1-2
2. IMPORTANT INFORMATION 2-1
2.1 Receiving and Unpacking Equipment 2-1
2.2 General 2-1
2.3 Principles of Operation 2-3
2.4 Rating Plate 2-3
2.5 Pre-Installation 2-4
2.6 Equipment Installed at High Altitudes 2-5
2.7 Air Supply and Ventilation 2-5
2.8 Conversion of Units 2-6
3. INSTALLATION INSTRUCTIONS 3-1
3.1 Installing the Fryer 3-1
3.2 Leg and Caster Installation 3-1
3.3 Leveling the Fryer 3-2
3.4 Gas Connections 3-4
3.5 Adjustments/Adaptation to Different Gases 3-8
3.6 Gas Inputs 3-8
3.7 Gas Conversion Procedures 3-10
3.8 Gas Conversion Components 3-11
3.9 Electrical Connections 3-12
Page 5
24G Series Flatbottom Gas Fryers (CE)
Installation & Operation Manual
TABLE OF CONTENTS (CONT.)
Page #
4. FRYER OPERATIONS 4-1
4.1 Initial Start-up 4-1
4.2 Boil-Out Procedure 4-3
4.3 Final Preparation 4-6
5. THERMATRON OPERATION 5-1
5.1 Operating Fryers with Thermatron Controllers 5-1
6. PREVENTATIVE MAINTENANCE 6-1
6.1 General 6-1
7. TROUBLESHOOTING 7-1
7.1 Pilot Burner Malfunction 7-1
7.2 Main Burner Malfunctions 7-2
7.3 Thermatron Calibration 7-3
7.4 Wiring Diagrams 7-4
7.5 Recommended Spare Parts 7-6
Page 6
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 1: INTRODUCTION
1.1 Applicability and Validity
The Dean 24G Series Flatbottom gas model family has been approved by the European Union
(EU) for sale and installation in the following EU countries: AT, BE, KE, KD, ES, FI, FR, GB,
IE, IT, LU, NL, NO, PT and SE.
This manual is applicable to and valid for all Dean 24G Flatbottom gas units sold in Englishspeaking countries, including those in the European Union. Where conflicts exist between
instructions and information in this manual and local or national codes of the country in which
the equipment is installed, installation and operation shall comply with those codes.
This appliance is only for professional use and shall be used by qualified personnel as defined
in Section 1.5.
1.2 Ordering Parts
Customers may order parts directly from their local Authorized Parts Distributor. For this address
and phone number, contact your maintenance and repair center or call the factory. The factory
address and phone numbers are on the back cover of this manual.
To speed up your order, the following information is required:
Model Number
Serial Number
Optional Equipment
Item Part Number
Quantity Needed
Type
1.3 Service Information
Call the 1-800-551-8633 or (318) 865-1711 Service Hotline number for the location of your nearest
maintenance and repair center. Always give the model and serial numbers of your fryer.
To assist you more efficiently, the following information will be needed:
Model Number
Serial Number
Optional
Equipment
Nature of Problem
Type
Additional information (i.e. cooking environment, time of day, and other pertinent
information) may be helpful in solving your service problem.
1-1
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24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 1: INTRODUCTION
1.4 Safety Information
Before attempting to operate your unit, read the instructions in this manual thoroughly.
Throughout this manual, you will find notations enclosed in double-bordered boxes similar to the
ones below.
CAUTION boxes contain information about actions or conditions that may cause or result in a
malfunction of your system.
CAUTION
Example of a CAUTION box.
WARNING boxes contain information about actions or conditions that may cause or result in
damage to your system, and which may cause your system to malfunction.
WARNING
Example of a WARNING box.
DANGER boxes contain information about actions or conditions that may cause or result in injury
to personnel, and which may cause damage to your system and/or cause your system to malfunction.
DANGER
Hot cooking oil causes severe burns. Never attempt to move a fryer containing hot
cooking oil or to transfer hot cooking oil from one container to another.
1.5 Service Personnel
1.5.1 Definitions
A. Qualified and/or Authorized Operating Personnel
1. Qualified/authorized operating personnel are those who have carefully read the information
in this manual and have familiarized themselves with the equipment functions, or have had
previous experience with the operation of equipment covered in this manual.
1-2
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24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 1: INTRODUCTION
1.5.1 Definitions (cont.)
B. Qualified Installation Personnel
1. Qualified/authorized personnel are those who have carefully read the information in this
manual and have familiarized themselves with the equipment functions, or who have had
previous experience with the operation of the equipment covered in this manual.
C. Qualified Service Personnel
1. Qualified service personnel are those who are familiar with Dean equipment and have been
authorized by Dean to perform service on Dean equipment. All authorized service
personnel are required to be equipped with a complete set of service parts manuals and stock
a minimum amount of parts for Dean equipment. A list of Dean Factory Authorized Service
Centers (FASCs) was included with the fryer when shipped from the factory. Failure to use
qualified service personnel will void the Dean warranty on your equipment.
1-3
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24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 2: IMPORTANT INFORMATION
2.1 Receiving and Unpacking Equipment
A. Check that the container is upright. Use an outward prying motion - no hammering - to remove
the carton. Unpack the fryer carefully and remove all accessories from the carton. Do not discard
or misplace accessories. They will be needed.
B. After unpacking, immediately check the equipment for visible signs of shipping damage. If
damage has occurred, contact the carrier and file the appropriate freight claims. Do not contact
the factory. Shipping damage responsibility is between the carrier and the dealer.
If your equipment arrives damaged:
1. File claim for damages immediately, regardless of extent of damage.
2. Visible loss or damage: Be sure this is noted on the freight bill or express receipt and is
signed by the person making the delivery.
3. Concealed loss or damage: If damage is unnoticed until equipment is unpacked, notify
freight company or carrier immediately, and file a concealed damage claim. The claim
should be filed within 15 days of date of delivery. Be sure to retain container for inspection.
NOTE: Dean Does Not Assume Responsibility for Damage or Loss Incurred in
C. Move the fryer to the location of installation and install legs and/or casters as described in
D. Remove all plastic skin from sides, front, and doors of the fryer(s). Failure to do this prior to
2.2 General
Transit.
Chapter 3.2.
initial fryer operation will make it very difficult to remove later.
Qualified, licensed, and/or authorized installation or service personnel only (as defined in
Section 1.5) should perform the following:
?? Installation and service on Dean equipment.
?? Conversion of this appliance from one gas type to another.
Failure to use qualified, licensed, and/or authorized installation or service personnel to install,
convert to another gas type or otherwise service this equipment will void the Dean warranty
and may result in damage to the equipment or injury to personnel.
2-1
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24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 2: IMPORTANT INFORMATION
2.2 General (cont.)
Where conflicts exist between instructions and information in this manual and local code or
national codes, or regulations, installation and operation shall comply with the codes or
regulations in force in the country in which the equipment is installed.
DANGER
Building codes prohibit a fryer with its open tank of hot oil/shortening from being installed
beside an open flame of any type, including those of broilers and ranges.
Upon arrival, inspect the fryer carefully for visible or concealed damage. (See Receiving and
Unpacking Equipment in Section 2.7.)
CAUTION
Dean appliances equipped with legs are for stationary installations. Appliances fitted with
legs must be lifted during movement to avoid damage to the appliance and bodily injury.
For moveable installations, optional equipment casters must be used. Questions? Call 1-
800-551-8633
2.2.1 Fryer Description
Dean 24G Series Flatbottom gas fryers are energy efficient, open frypot, gas-fired units. All units
are shipped completely assembled, with accessories packed inside the frypot. All units are adjusted,
tested, and inspected at the factory prior to crating for shipment.
Base units described below are designed for use in a commercial food preparation environment after
installation as outlined in this manual.
MODEL 1824G 2424G
FRYING VESSEL
Frying Area:
Oil Capacity
ENERGY REQUIREMENTS:
Gas (Nat or Pro.)
Electrical
APPROXIMATE SHIPPING WEIGHT (kg)
45.7 x 61 cm
23-35 kg
120,000 BTU/Hr
230V/50~1Ø
129 138
61 x 61 cm
33-45 kg
2-2
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24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 2: IMPORTANT INFORMATION
2.3 Principles of Operation
The frypot is constructed of welded steel with heat transfer ducting on the frypot-bottom for efficient
heating of oil without scorching.
Base units come with painted cabinetry or optional stainless steel. Base units come with 15-cm (6inch) adjustable legs or optional 13-cm (5-inch) casters. Multiple units come with casters.
Dean 24G Series Flatbottom gas fryers come with an operating thermostat for reliable temperature
control. Fryers can be ordered with a Thermatron temperature controller (optional) and/or boil-out
feature (optional-only available with Thermatron controller), or a computer controller (optional).
A draft inducer draws air over the burners for combustion. Air movement directs the combustion
products back and forth across the frypot bottom by means of a set of baffles, transferring the heat
evenly across the frypot bottom. Cold air is prevented from entering the combustion chamber and
cooling the oil during the coasting cycle.
2.3.1 Automatic Safety Features
?? High oil temperature detection to shut off power to the main burners through the solenoid-
actuated gas valve.
?? Combination safety gas valve includes built-in pressure regulator and pilot safety.
?? Sail switch built into outlet duct shuts off gas to the burners in the event of blower failure.
?? Optional safety switch built into the drain valve prohibits burner ignition if the valve is not
completely closed.
2.4 Rating Plate
The rating plate can be found on the inside panel of the fryer door. Information on this plate
includes the model and serial numbers, kW/hr (BTU/hr) of the burners, outlet gas pressure in mbars
(inches W.C.), and configuration: natural or propane gas. Rating plate data is essential for proper
unit identification, communicating with the factory or requesting special parts and/or information.
The rating plate is located inside the front door panel. Information provided includes the model and
serial number of the fryer, kW/hr (BTU/hr) of the burners, outlet gas pressure in mbars (inches
W.C.) and whether the unit has natural or propane gas orifices.
DANGER
Fryers MUST be connected ONLY to the gas-type identified on the attached rating
plate.
2-3
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24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 2: IMPORTANT INFORMATION
2.5 Pre-Installation
DANGER
No structural material on the fryer should be altered or removed to accommodate
placement of the fryer under a hood. Questions? Call the Frymaster/Dean Service
Hotline at 1-800-551-8633.
DANGER
Do not connect this appliance to the gas supply before reviewing all information in
this chapter.
A. General: Only licensed personnel (as defined in Section 1.5) should install any gas-fired
equipment.
1. A manual gas shut-off valve must be installed in the gas supply line ahead of the fryers for
safety and ease of future service.
2. Dean 24G Series Flatbottom gas fryers require 230VAC and are equipped with a 16-3 SJT
power cord.
B. Clearances: The fryer area must be kept free and clear of all combustibles. This unit is design-
certified for the following installations:
1. Commercial installation only (not for household use).
2. Non-combustible floor installation equipped with factory-supplied 15 cm (6-inch) adjustable
legs or 13 cm (5-inch) casters;
3. Combustible construction with a minimum clearance of 15 cm (6-inch) side and 15 cm (6inch) rear, and equipped with factory-supplied 15 cm (6-inch) adjustable legs or 13 cm (5inch) casters.
C. Installation Standards
1. CE/EXPORT STANDARDS: Fryer installation must conform with local codes, or in the
absence of local codes, to the appropriate national or European Community (CE) standards.
2-4
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24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 2: IMPORTANT INFORMATION
2.6 Equipment Installed at High Altitudes
1. The fryer input rating (kW/hr) is for elevations up to 610 m (2,000 feet). For elevations
above 610 m (2,000 feet), the rating should be reduced 4 percent for each additional 305-m
(1,000 feet) above sea level. The correct orifices are installed at the factory if the operating
altitude is known at the time of the customer’s order.
2.7 Air Supply and Ventilation
DANGER
This appliance must be installed with sufficient ventilation to prevent the occurrence
of unacceptable concentrations of substances harmful to the health of personnel in
the room in which it is installed.
1. Keep the area around the fryer clear to prevent obstruction of combustion and ventilation
airflow.
2. Do not connect this fryer to an exhaust duct.
3. Correct installation and adjustment will ensure adequate airflow to the fryer system.
4. A commercial, heavy-duty fryer must vent its combustion wastes to the outside of the
building. A deep-fat fryer must be installed under a powered exhaust hood, or an exhaust
fan must be provided in the wall above the unit, as exhaust gas temperatures are
approximately 260-316°C (500-600°F). Check air movement during installation. Strong
exhaust fans in the exhaust hood or in the overall air conditioning system can produce slight
air drafts in the room.
5. Do not place the fryer’s flue outlet directly into the plenum of the hood, as it will affect the
gas combustion of the fryer.
6. Never use the interior of the fryer cabinet for storage or store items on shelving over or
behind the fryer. Exhaust temperatures can exceed 316°C (600°F) and may damage or melt
items stored in or near the fryer.
7. Adequate distance must be maintained from the flue outlet of the fryer(s) to the lower edge
of the exhaust filter bank. Per NFPA Standards No. 96, a minimum of 45-cm (18 inches)
should be maintained between the flue(s) and the lower edge of the exhaust hood filter.
8. Filters and drip troughs should be part of any industrial hood, but consult local codes before
constructing and installing any hood. The duct system, the exhaust hood and the filter bank
must be cleaned on a regular basis and kept free of grease.
2-5
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24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 2: IMPORTANT INFORMATION
2.8 Conversion of Units
Pressure:
1 mbar = 10,2 mm W.C. = 0,4-inch W.C.
20 mbar = 204 mm W.C. = 8-inch W.C.
1-inch W.C. = 25,4 mm W.C. = 2,5 mbar
Heat Input:
1 kW = 3410 BTU/hr
100 BTU/hr = 0,0293 kW
Temperature:
0° Celsius = 32° Fahrenheit
Temperature in degrees Celsius = (Temperature in degrees Fahrenheit (F) – 32) x 0,555
100° Celsius = (212° Fahrenheit – 32) x 0,555
2-6
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24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 3: INSTALLATION INSTRUCTIONS
3.1 Installing the Fryer
A. Initial Installation: If installed with legs, do not push against the fryer’s side to adjust its
position. Use a pallet or lift jack to lift the fryer slightly and place it where it is to be installed.
B. Relocating the Fryer: If relocating a fryer installed with legs, remove all weight from each leg
before moving.
Note: If a leg becomes damaged during movement, contact your service agent for immediate
repair/replacement.
CAUTION
Fryers may not function properly if curb mounted.
DANGER
This fryer may tip and cause personal injury if not secured correctly in a stationary
position. Drain all oil/shortening from fryer before moving. Hot oil will splash and
cause severe burns upon contact.
3.2 Leg and Caster Installation
A. General
1. Install legs and rear rigid casters near where the fryer is to be used, as neither are secure for
long transit. Unit cannot be curb mounted and must be equipped with the legs and casters
provided.
2. When positioning the fryer, gently lower the fryer into position to prevent undue strain to
the legs and internal mounting hardware. Use a pallet or lift jack to lift and position the
fryer if possible. Tilting the fryer may damage the legs.
3. The rigid casters must be installed on the fryer rear channel assembly only.
4. Proceed to Step 3.3, Leveling the Fryer, after legs and rear rigid casters are installed.
3-1
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24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 3: INSTALLATION INSTRUCTIONS
3.2 Leg and Caster Installation (cont.)
B. Leg and Rigid Caster Installation
1. Remove unit from pallet.
2. Carefully raise the unit with a forklift, pallet jack, or other steady means.
3. Place one lock washer on each hex head screw.
4. Insert hex head screws with lock washers [1/4-20 threads by ¾" long] through bolt holes of
leg mounting plates and mount to the front channel. Mount rigid casters to the rear channel
following the same procedure. A locknut has been attached to the topside of the base
mounting plates at the factory to capture the hex head screw as it is screwed in.
5. Tighten the bolts to 5.65 Nm (50 inch-lbs.) torque.
CAUTION
For caster retrofit, the unit must be at room temperature and drained of shortening
before installing the casters.
3.3 Leveling the Fryer
A. Place a carpenter’s spirit level across the top of the fryer and level the unit front to back. If the
fryer is not level from side to side, a platform or other surface adjustment is needed; there are no
side-to-side level adjustments on a fryer equipped with caster/leg combinations. (If a fryer is
equipped with legs only, side-to-side level adjustments can be made. If a fryer is equipped with
casters only, no level adjustments to the fryer can be made.) If the fryer is not level, the unit may
not function efficiently, the oil may not drain properly for filtering and in a multi-fryer battery, it
may not match adjacent units.
Legs (Only)
1. Adjust leg height with an adjustable or open-end wrench by turning the hex bullet on the
bottom of the leg.
2. The hex bullet is for minor leg height adjustment only. Do not adjust more than 22 mm.
3. When leveling the unit, the leg body should be held firmly to keep the leg from bending or
rotating while turning the hex bullet foot to the required height.
3-2
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24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 3: INSTALLATION INSTRUCTIONS
3.3 Leveling the Fryer (cont.)
Rigid Casters (Only)
1. Install the rigid casters on the fryer rear channel only. Legs must be installed on the front
channel.
2. There are no level adjustments for the rigid casters.
B. If the floor is uneven or has a decided slope, place the fryer on a level platform.
C. If the fryer is moved, re-level the fryer following the instructions given in Steps 3.3, A-B.
D. An installed fryer must be restrained to prevent tipping, which could splash hot oil. Restraints
can be straps or chains anchored to an immovable object (wall, floor anchor), or the manner of
installation (installing the fryer in an alcove, battering to other appliances, etc.).
E. Installing Optional Swivel Casters:
1. Install non-locking casters only at the rear of the unit.
2. Locking casters must be installed at the front of the unit. Locking casters allow the fryer to
be "locked" in position for safe operations.
3. Follow the same instructions for leg installations as given above in steps 3.2, B1-5.
Front View
1/4-20 x 3/4 Hex Bolt
Rear Side View
Optional Caster-
Rear Only
Optional Caster-
Front Only
Front Channel
or Rear Channel
Front or Rear Leg with
Mounting Plate
Adjust as needed
Front Channel or
Rear Channel
Leg Support Assembly
Washer
1/4-20 Hex Head Locknut
1/4-20 x 3/4 Hex Bolt
Rear Caster—5" Rigid
Leg and Caster (Optional) Mounting Installation
3-3
Front Caster—5" Swivel
w/Brake
Page 18
Supply Pressures and Gas
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 3: INSTALLATION INSTRUCTIONS
3.3 Leveling the Fryer (cont.)
NOTE: The installation must be inspected after it is complete to ensure it meets the intent of
these instructions. The on-site supervisor and/or operator(s) should be informed that the
appliance is installed with restraints. If restraints are removed to move fryer (cleaning
beneath and behind, relocation, etc.), ensure that they are re-installed when fryer is returned
to its permanently installed position.
CAUTION
The fryer MUST be connected to the gas supply specified on the rating and serial number
plate located on the back of the fryer door.
WARNING
If gas odors are detected, the gas supply MUST be shut off at the main shut-off valve. The
local gas company or FASC should be contacted immediately to rectify the problem.
3.4 Gas Connections
Dean 24G Series Flatbottom gas fryers have obtained CE markings for countries and gas categories
shown below:
Countries
BE Belgium
DE Germany
DK Denmark G20 20 I2H
ES Spain
FR France
GB Great Britain
GR Greece
IR Ireland
IT Italy G20 20 I2H
LU Luxembourg
NL The Netherlands
PT Portugal
(mbar)
G20 20/25
G31 37
G20 20 I2E
G31 50 I3P
G20 20
G31 37 and 50
G20/G25 20/25
G31 37 and 50
G20 20
G31 37
G20 20
G31 37 and 50
G20 20
G31 37
G20/G25 20/25
G31 50
G25 25
G31 50
G20 20
G31 37
Appliance Categories
IIE(R)B3P
II2H3P
II2ESI3P
II2H3P
II2H3P
II2H3P
II2E3P
II2L3P
II2H3P
3-4
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24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 3: INSTALLATION INSTRUCTIONS
3.4 Gas Connections (cont.)
DANGER
Before connecting new pipe to this appliance the pipe must be blown out thoroughly
to remove all foreign material. Foreign material in the burner and gas controls will
cause improper and dangerous operation.
The gas supply (service) line must be the same size or greater than the fryer inlet line. Dean 24G
Series Flatbottom gas fryers are equipped with 22 mm male ISO 7.1 inlet. The gas supply line must
be sized to accommodate all gas-fired equipment connected to that gas supply. Consult local gas
companies or suppliers, or your local contractor for minimum supply line requirements.
Supply Line Specifications
The gas supply lines must be sized as indicated in the chart below, based on the total number of
fryers connected to the main gas supply.
Gas Types Number of Fryers
1 2 to 3 4 or more (*)
G20 and G25 22 mm 28 mm 35 mm
G31 15 mm 22 mm 28 mm
(*) When exceeding 6 meters for a configuration of more than four fryers, it is necessary to
provide a 33 mm rigid gas connection.
Recommended Gas Supply Line Sizes
DANGER
All connections must be sealed with a joint compound suitable for the gas being
used and all connections must be tested with a solution of soapy water before
lighting any pilots.
Never use matches, candles, or any other ignition source to check for leaks. If gas
odors are detected, shut off the gas supply to the appliance at the main shut-off
valve and immediately contact the local gas company or an authorized service
agency for service.
DANGER
"Dry-firing" your unit will cause damage to the frypot and can cause a fire. Always
ensure that melted shortening, cooking oil or water is in the frypot before firing the
unit.
3-5
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24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 3: INSTALLATION INSTRUCTIONS
3.4 Gas Connections (cont.)
Rigid Connections
Check any installer-supplied intake pipe(s) visually and clean metal particles or other foreign matter
from the threads before installing into a service line. If the intake pipes are not clear of all foreign
matter, the orifices will clog when gas pressure is applied. When using thread compound on gas
piping, use very small amounts and only on male threads. Use a pipe thread compound that is not
affected by the chemical action of G31 gases. DO NOT apply thread compound to the first two pipe
threads – doing so will cause clogging of the burner orifices and control valve.
Manual shut-off valve
This gas service supplier-installed valve must be installed in the gas service line ahead of the fryers
in the gas stream and in a position where it can be reached quickly in the event of an emergency.
Regulating Gas Pressure
The fryer and shut-off valve must be disconnected from the gas supply during any pressure testing of
the system.
External gas regulators are not normally required on this fryer. A safety control valve protects the
fryer against pressure fluctuations. If the incoming pressure is in excess of 3,45 kPa/35,0 mbar, a
step-down regulator will be required.
DANGER
When pressure-testing incoming gas supply lines, disconnect the fryer from the gas
line if the test pressure is 3,45 kPa (½" PSI, 14" W.C.) or greater to avoid damage to
the fryer’s gas piping and gas valve(s).
A. Manifold Pressure: Your local service technician should check the manifold pressure with a
manometer.
1. Check the rating plate for manifold gas pressures. See page 3-9 for gas types and pressures.
2. Confirm that the arrow forged into the bottom of the regulator body, which indicates gas
flow direction, is pointed downstream towards the fryers. The air vent cap is also part of the
regulator and should not be removed.
3. If a vent line from the gas pressure regulator is used, it should be installed in accordance
with local codes or in the absence of local codes, with the appropriate national or European
Community (CE) standards.
WARNING
Use a diluted soap solution to find gas leaks when making new connections.
3-6
Page 21
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 3: INSTALLATION INSTRUCTIONS
3.4 Gas Connections (cont.)
B. Regulators: Gas regulators can be adjusted in the field, but no adjustments should be made unless
the regulator is out of adjustment, or serious pressure fluctuations are observed.
C. Only qualified service personnel should make adjustments to the regulators.
D. Orifices: The fryer can be configured to operate on any available gas. The correct safety control
valve, appropriate gas orifices, and pilot burner are installed at the factory. While the valve can
be adjusted in the field, only qualified service personnel should make any adjustments with the
proper test equipment.
1. The following color codes indicate the type of gas to be used for each fryer and associated
components.
Gas Type CE Color Code
G20 and G25 Blue
G31 Red
E. Flexible Couplings, Connectors and Casters
1. If the fryer is to be installed with flexible couplings and/or quick-disconnect fittings, the
installer must use a heavy-duty certified commercial flexible connector of at least 22 mm
NPT (with suitable strain-relief attachments), in compliance with local codes or in the
absence of local codes, with the appropriate national or European Community (CE)
standards. Quick-disconnect devices must comply with local codes or in the absence of
local codes, with the appropriate national or European Community (CE) standards.
2. For an appliance equipped with casters, the installation shall be made with a connector that
complies with local codes or in the absence of local codes, with the appropriate national or
European Community (CE) standards.
3. Under no circumstances are the connector and the quick-disconnect device, or its associated
piping to be used to limit fryer movement. A restraining bracket is provided on the appliance
structural back to prevent the unit from moving from its installed position.
WARNING
Do not attach accessories to this fryer unless fryer is secured from tipping. The
fryer may become unstable, tip over and cause injury.
3-7
Page 22
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 3: INSTALLATION INSTRUCTIONS
3.4 Gas Connections (cont.)
4. To limit movement of the fryer, restraints independent of the flexible coupling or connector
must be used. Clips are located on the back panel of the fryer for the attachment of
restraints.
5. If disconnection of the restraint is necessary, the restraint must be reconnected after the fryer
has been returned to its originally installed position.
F. After hook up, bleed the gas line of air to ensure that the pilot light will ignite quickly and
evenly.
3.5 Adjustments/Adaptation To Different Gases
WARNING
Qualified personnel MUST perform any adaptation, modification, or gas conversion,
if required. Failure to use qualified personnel will void the Dean warranty.
1. Proper operation of appliances requires operator to inspect the following adjustments in
Section 3.6 in terms of gas inputs and pressures.
2. Dean 24G Series Flatbottom gas fryers are manufactured to use the type of gas and pressure
specified on the rating plate. When changing gas, adaptation must be performed by
qualified personnel as defined in Section 1.5. Failure to use qualified personnel will void
the Dean warranty.
3.6 Gas Inputs
Nominal Heat Inputs (Qn), Gas Type, Orifice Size, Part Number and Quantity/Color are listed in the
table below:
MODEL NOMINAL HEAT
INPUT- Qn
(kW)
GAS TYPE ORIFICE SIZE
(MM)†
ORIFICE
PART NO.
ORIFICE
QTY/ COLOR
24G Series
(ALL)
†Orifice size listed is for fryers operating at altitudes of 610 meters or less.
30
G20
G25
G31
2,50
2,50
1,60
1826-40
1826-40
810-2317
3/BLUE
3/BLUE
3/RED
3-8
Page 23
ve requirements 5 to 10 minutes after the
11. (Pilot Flame Adjustment: Turn
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 3: INSTALLATION INSTRUCTIONS
3.6 Gas Inputs (cont.)
Adjustments for different gases are as follows:
GAS PRESSURE AT
REGULATOR
MBAR INCH W.C.
MODEL
ORIFICE SIZE
(MM)†
GAS TYPE
BURNER AIR
BURNER
MARKING
PILOT
MARKING
ADJUSTMENT
(SEE
ILLUSTRATION
PAGE 3-9)
24G
Series
NOTE: Outlet gas pressure must be adjusted strictly within the abo
appliance is operating.
For controls and adjustments, please refer to the gas valve illustration on page 3the pilot adjustment screw clockwise/counter-clockwise until the desired flame-volume is achieved).
† Orifice size listed is for fryers operating at altitudes of 610 meters or less.
* Except Belgium (BE). G20 and G25 remain the same: 14,5 mbar.
2,50
2,50
1,60
G20
G25*
G31
14,5
21,0
31,0
5,8
8,4
12,44
Blue
Blue
Red
26N
26N
16LP
Opening- Maximum
Opening- Maximum
Opening- 15-mm
Burner Adjustments- 24G Series
Loosen this screw to
adjust burner damper
for optimum flame.
Ensure orifice tip is approximately
20 mm from the upper damper slot.
If gas odors are detected, the gas supply MUST be shut off at the main shut-off
valve, and the local gas company or authorized service agency contacted for
20 mm
G20/G25 Gas: Maximum Opening
G31 Gas: 15 mm Opening
WARNING
immediate service.
3-9
Page 24
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 3: INSTALLATION INSTRUCTIONS
3.7 Gas Conversion Procedures
DANGER
This appliance was configured at the factory for a specific type of gas. Converting
from one gas type to another requires the installation of specific gas-conversion
components.
Switching to a different type of gas without installing the proper conversion
components may result in fire or explosion. NEVER ATTACH THIS APPLIANCE TO A
GAS SUPPLY FOR WHICH IT IS NOT CONFIGURED!
Conversion of this appliance from one type of gas to another should only be
performed by qualified, licensed, and authorized installation or service personnel, as
defined in Section 1.5 of this manual.
See page 3-11 for gas valve illustration when performing the following conversions.
When converting from G20 to G25 gas, the following procedures apply:
? ? Equipment replacement is not required.
? ? Adjust orifice gas pressure to the appropriate value listed in the table on page 3-9 by turning
the gas valve "adjustment screw".
? ? After adjustment, replace the adjustment-screw cover.
When converting from G20 (or G25) gas to G31 propane (or vice-versa), the following procedures
apply:
? ? Burner orifices and pilot orifice MUST be replaced.
? ? Adjust orifice gas pressure to the appropriate value listed in the table on page 3-9 by turning
the gas-valve adjustment screw.
? ? After adjustment, replace the adjustment-screw cover.
? ? Factory MUST be notified so the conversion can be documented and a new rating plate can
be sent out.
When converting from G20 (20 mbar) to G25 (25 mbar), or vice-versa, or G31 (37 mbar) to G31 (50
mbar), the following procedures apply:
? ? Check pilot-adjustment and adjust as necessary.
? ? Other adjustments are not necessary.
3-10
Page 25
Contact factory at time of
Contact factory at time of
r
Typical CE Gas
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 3: INSTALLATION INSTRUCTIONS
3.7 Gas Conversion Procedures (cont.)
Conversion from one gas family to another (i.e. changing from natural gas to propane) requires
special components. Obtain the necessary components using the cross-reference in Section 3.8, Gas
Conversion Components.
Conversions can only be executed by qualified, factory-authorized personnel.
Thermocouple connectionPilot flow adjustment
Valve (24V)
Vent tube connection
ON Button- Pilot Gas-flowOFF ButtonPressure flow adjustment
3.8 Gas Conversion Components
Use the following components to convert from natural gas to propane and vice-versa. See Section
3.6 for orifice quantities required for conversion.
Natural Gas to Propane Components Propane To Natural Gas Components
REF DESCRIPTION REF DESCRIPTION
810-2400 Pilot orifice (16LP) 810-0811 Pilot orifice (26N)
810-2317
Burner orifice
(diameter: 1.60 mm)†
1826-40
Burner orifice
(diameter: 2.50 mm)†
New Rating
†Burner orifices listed are for fryers operating at altitudes of 610 meters or less. Fo
altitudes greater than 610 meters, contact the factory for the correct orifice size.
Plate
conversion.
New Rating
3-11
Plate
conversion.
Page 26
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 3: INSTALLATION INSTRUCTIONS
3.9 Electrical Connections
The fryer when installed must be electrically grounded in accordance with local codes, or in the
absence of local codes, with the appropriate national or European Community (CE) standards.
DANGER
This fryer is equipped with a three-prong (grounding) plug for protection against
electrical shock and must be plugged directly into a properly grounded, three-prong
receptacle. DO NOT CUT, REMOVE, OR OTHERWISE BYPASS THE GROUNDING
PRONG ON THIS PLUG!
The rating plate and wiring diagram are located inside the front door. The fryer is equipped with a
230VAC single-phase 50-hertz system (International/CE). Do not cut or remove the ground prong
from the power cord plug. Do not attempt to use the fryer during a power outage.
DANGER
This appliance requires electrical power for operation. Place the gas control valve in
the OFF position in case of a prolonged power outage. Do not attempt to operate
this appliance during a power outage.
3-12
Page 27
24G SERIES FLATBOTTOM GAS FRYERS (CE)
limit probe, drain
guard
CHAPTER 4: FRYER OPERATIONS
4.1 Initial Start-up
WARNING
The on-site supervisor is responsible for ensuring that operators are made aware of
the inherent hazards of operating a hot oil frying system, particularly the aspects of
system operation, oil filtration, draining and cleaning procedures.
Cleaning: New units are wiped clean with solvents at the factory to remove any visible signs of dirt,
oil, grease, etc. remaining from the manufacturing process, then coated lightly with oil. Before any
food preparation, wash thoroughly with hot, soapy water to remove any film residue and dust or
debris then rinse out and wipe dry. Also wash any accessories shipped with the unit. Close the drain
valve completely and replace the drain plug. Ensure the temperature sensing probe is adjusted
properly (see illustration).
Ensure probe tip is 1/8" from fry
vessel bottom for proper
temperature sensing.
Sensor Probe Guard
High-Limit/Temperature
Probe location
Fry Vessel Bottom
Sensor/highplug and sensor probelocation.
Vessel Drain Plug
WARNING
Do not bang fry baskets or other utensils on the fryer’s joiner strip. The strip is
present to seal the joint between the frypot. Banging fry baskets on the strip to
dislodge shortening will distort the strip, adversely affecting its fit. It is designed for
a tight fit and should only be removed for cleaning.
DANGER
Never operate this appliance with an empty frypot. The frypot must be filled with
water or cooking oil/shortening before lighting the burners. Failure to do so will
damage the frypot and may cause a fire.
4-1
Page 28
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 4: FRYER OPERATIONS
4.1.1 Pilot Lighting Procedures
Initial Pilot Lighting: All Dean fryers are tested, adjusted and calibrated to sea level conditions
before leaving the factory. Adjustments to assure proper operation of pilot may be necessary on
installation to meet local conditions, low gas pressure, differences in altitude and variations in gas
characteristics. These adjustments correct possible problems caused by rough handling or vibration
during shipment, and are to be performed only by qualified service personnel. These adjustments
are the responsibility of the customer and/or the dealer and are not covered by the Dean warranty.
The inlet pipe at the lower rear of the fryer brings incoming gas to the pilot safety control valve, then
to the pilot and main burners. The pilot is located high in the cabinet, at the base of the frypot.
WARNING
When checking for burner ignition or performance, do not get too close to the
burners. Slow ignition can cause possible flashback, increasing the potential for
facial and body burns.
Ensure that the following steps are done in sequence before lighting or re-lighting the pilot:
1. Turn off the manual shut-off valve on the incoming service line.
2. Turn the operating thermostat "OFF".
3. Depress the Pilot Off button (red) on the safety control valve to turn "OFF".
4. Wait at least 5 minutes for any accumulated gas to disperse.
5. Fill the frypot with oil or water to the OIL LEVEL line scribed on the frypot back.
6. Open the manual shut-off valve on the incoming service line.
7. Apply a lighted match or taper to the pilot burner head. (If fryer is equipped with a piezo ignitor,
go to Step 8).
8. Press the white pilot light button on the gas valve and hold approximately 45 seconds to 1
minute, until the pilot stays lit. (If fryer is equipped with a piezo ignitor, press and hold the
white pilot light button, then repeatedly press the piezo ignitor button until the pilot lights.
Release the white button after approximately 45 seconds to 1 minute.)
9. If the pilot does not stay lit, depress the white pilot light button and re-light the pilot, holding the
button in longer before releasing. Trapped air may necessitate re-lighting the pilot several times
until a constant gas flow is attained.
10. When the pilot stays lit, release the white pilot light button.
11. Turn the thermostat to any "ON" setting and ensure the main burner ignites from the pilot.
4-2
Page 29
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 4: FRYER OPERATIONS
4.1.2 Pilot Lighting Procedures, Electronic Ignition Systems
WARNING
Never use a match or taper to light pilot on this ignition system.
1. Turn gas "ON".
2. Turn electric power "ON" with the appropriate rocker switch or controller/computer.
3. The ignition module will energize the pilot gas supply and the ignitor. The ignitor spark will
ignite the pilot gas. The presence of the pilot flame is then proved by a flame sensor, which
sends a signal to the main gas supply, opening the valve. The operating thermostat or
computer/controller controls the fryer after ignition.
WARNING
In the event of prolonged power failure, the ignition module will shut down and lock
out the system. Turn the unit power "OFF" and then back "ON" after power has been
re-established.
4. If the pilot flame fails, the ignition module will shut down and lock out the system. To restart,
turn the electric power off, wait approximately 5 minutes for the system to recycle itself, then
turn the power on again. Repeat Steps 1-3.
4.2 Boil-Out Procedure
DANGER
Never leave the fryer unattended during the boil-out process. If the boil-out solution
boils over, turn the fryer off immediately and let the solution cool for a few minutes
before resuming the process.
WARNING
Do not drain boil-out solution into a shortening disposal unit, a built-in filtration unit,
or a portable filter unit. These units are not intended for this purpose, and will be
damaged by the solution.
DANGER
Remove all drops of water from the frypot before filling with cooking oil or
shortening. Failure to do so will cause spattering of hot liquid when the oil or
shortening is heated to cooking temperature and may cause injury to nearby
personnel.
4-3
Page 30
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 4: FRYER OPERATIONS
4.2 Boil-Out Procedure (cont.)
1. Empty frypot and pour in cleaning solution concentrate. Add water to the OIL LEVEL line
scribed in the back of the frypot.
2. Operating thermostat-equipped fryers: Set dial/temperature controller to 225°F (107ºC), just
above that of boiling water.
3. Filtration/Boil-Mode-equipped fryers: Turn fryer power switch to "ON". Press the fryer- reset
switch (if applicable). Turn the boil-out switch "ON".
4. The main burner will ignite.
5. Operating thermostat-equipped fryers: Reset the thermostat-dial to 93°C (200°F).
6. The burners should shut off, just as the boil-out solution reaches setpoint.
CAUTION
If the pilot and main burner go out, the fryer(s) MUST be left completely shut down
at least 5 minutes before lighting.
7. The burners will heat the boil-out solution to a simmer. Simmer the solution for approximately
45 minutes. Wearing protective gloves, scrub the bottom and sides of the frypot with the frypot
brush (optional on certain models), being careful not to disturb the temperature sensing probes
and the high-limit thermostat.
CAUTION
Do not leave fryer unattended. The boil-out solution may foam and overflow if fryer is
left unattended. If this happens, turn thermostat and gas valve off. Resume boil out
when foam dissipates.
8. Do not allow the water level to decrease below OIL LEVEL line in frypot during boil-out
operation.
4-4
Page 31
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 4: FRYER OPERATIONS
4.2 Boil-Out Procedure (cont.)
WARNING
Water or boil-out solution MUST not be allowed to drain into the filter pan or filter
system. Irreversible damage will result if water is allowed into the system.
9. Operating Thermostat-equipped fryers: After boil out is complete, turn the thermostat dial to
"OFF". Filtration/Boil-Mode-equipped fryers: After boil out is complete, turn the boil-out and
fryer switches to "OFF". Drain the solution from the frypot. Place a metal stockpot of sufficient
size to safely hold the entire contents of the frypot under the drain port to collect the water/boilout solution. Do not allow water or boil-out solution to drain into the filter pan. The filter pump
is not designed for water operation, and will be irreparably damaged (see warning statement
above).
10. Refill the frypot with fresh water and vinegar to neutralize any residual boil-out solution. Wash
all surfaces of the frypot. Drain completely and wipe down all surfaces of the frypot to
completely eliminate water from the frypot.
Important!
Refill frypot with oil or wipe frypot interior with oil immediately to prevent oxidation
and rust from forming.
NOTE: It is recommended that the boil-out procedure be performed each time the oil/shortening is
changed.
Computer-equipped fryers: See computer manual for boil-out programming and follow the
above procedures for boil-out.
WARNING
All drops of water MUST be removed from frypot before filling with cooking oil. Do
not turn fryer on to dry…extensive damage will occur to frypot, and ALL applicable
warranties will be voided.
DANGER
Do not go near the area directly over the flue outlet while the fryer is operating.
Always wear oil-proof, insulated gloves when working with the fryer filled with hot
oil.
Always drain hot oil into a metal stockpot of sufficient size to safely hold the entire
contents of the frypot.
4-5
Page 32
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 4: FRYER OPERATIONS
4.3 Final Preparation
WARNING
NEVER set a complete block of solid shortening in the frypot. To do so will damage
the frypot, and void the warranty.
4.3.1 Filling Fryer with Cooking Oil/Shortening
1. Ensure the drain valve is closed and the drain plug is in place. When using a liquid shortening,
fill the fryer to the OIL LEVEL line scribed into the back of the frypot.
2. When using a solid shortening, first melt it in a suitable container, or cut it into small pieces and
pack it into the frypot. Ensure the sensor probe cover is in place to prevent damage to the
sensing bulbs.
3. Operating Thermostat: Turn the burners "ON" for about 10 seconds, "OFF" for a minute, etc.,
until the shortening is melted. If you see smoke coming from the shortening while melting this
way, shorten the "ON" cycle and lengthen the "OFF" cycle. Smoke indicates potential scorching
of the shortening, which will shorten its useful life.
4. Compu-Fry Computer: Press the computer on/off switch to "ON". The burners will initially
operate in the MELT CYCLE mode until the shortening reaches 82°C (180°F). It will then
automatically switch to normal operation.
5. Thermatron with Melt Cycle Option Enabled: Set Thermatron to the working temperature. The
burners will cycle on approximately 5 seconds, and off for approximately 15 seconds until the
temperature reaches 66°C (150°F). The Thermatron will then switch to normal operation.
6. Before starting operation, set the Thermatron/Operating Thermostat or program the computer to
the probable working temperature and wait for the temperature to stabilize.
For additional computer instructions, see computer manual.
4-6
Page 33
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 5: THERMATRON OPERATION
5.1 Operating Fryers with Thermatron Controllers
24G Flatbottom Series gas fryers can come
equipped with a solid-state temperature
controller, or Thermatron
computer or basic thermostat. A Thermatron
system incorporates a temperature-control circuit
board, a potentiometer, and a temperature probe.
Thermatron systems are operated with the
following controls:
®
controller instead of a
Fryer Power Switch: Turns fryer on
and off.
Thermatron Temperature Controller
Drain Reset Switch
(Optional): Resets drain
Boil-Out Switch (Optional):
operates only in "Thermatron"
mode. When "ON", this switch
by-passes the Thermatron
melt-cycle and allows the
water temperature to reach
196°F.
High-Limit Reset Breaker
(location varies according to
system): This must be
manually reset if fryer
exceeds high-limit setpoint.
Manual Filter Power Switch (if
equipped with filter system):
Connects/disconnects power to
filter pump if primary system fails.
Fryer power switch should be
"OFF" when filter is in use.
O
F
F
O
F
F
POWER
FRYER
BOIL OUT
O
N
R
E
S
E
T
O
N
safety switch after closing
drain valve. Drain valve
must be completely closed
prior to resetting switch.
5 Amp (230VAC) Filter Reset
Breaker (if equipped with filter
system): Inline between the
filter pump and the filter power
switch. Ensure power is "OFF"
before resetting or replacing.
FRYER POWER SWITCH – This switch turns the fryer on and off. When the power switch is in
the "ON" position, the indicator light will be lit when calling for heat.
BOIL-OUT SWITCH –operates only when in the Thermatron mode. When the Boil-Out switch
is "ON", it will bypass the Thermatron melt cycle, and allow the water temperature to reach
approximately 196°F.
DRAIN RESET SWITCH (Optional) – Resets drain safety switch after draining the fryer. Drain
valve must be closed completely before resetting switch.
5-1
Page 34
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 5: THERMATRON OPERATION
5.1 Operating Fryers with Thermatron Controllers (cont.)
MANUAL FILTER POWER SWITCH (if equipped with filter system) – Controls power to the
filter pump in the event the primary system fails. Fryer Power Switch should be in "OFF"
position when in use.
HIGH-LIMIT RESET –Located under control panel. Must be manually reset if the fryer exceeds
high-limit setpoint.
FILTER RESET BREAKER (7 Amp Circuit Breaker- 120VAC or 5 Amp Circuit Breaker230VAC) – the breaker is inline between the filter switch and the pump. Ensure filter power is off
prior to resetting or replacing.
5 AMP (115VAC) or 2 AMP (230VAC) FUSE – each fryer circuit is protected by a 5 amp
(115VAC) or 2 amp (230VAC) fuse located under the control panel or inside the cabinet.
5-2
Page 35
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 6: PREVENTATIVE MAINTENANCE
6.1 General
DANGER
Never attempt to clean the fryer during the cooking process or when the frypot is
filled with hot oil/shortening. If water comes in contact with oil/shortening heated to
cooking temperature, it will cause spattering of the oil/shortening, which can result
in severe burns to nearby personnel.
Any equipment works better and lasts longer when maintained properly and kept clean. Cooking
equipment is no exception. 24G Series Flatbottom gas fryers should be kept clean during the
working day, and thoroughly cleaned at the end of each day. Below are recommendations for daily,
weekly and periodic preventative maintenance.
6.1.1 Daily
WARNING
Use a commercial grade cleaner formulated to effectively clean and sanitize food-
contact surfaces. Read the directions and precautionary statements for use.
Particular attention must be paid to the concentration of cleaner and the length of
time the cleaner remains on the food-contact surfaces.
A. Remove and wash all removable parts.
B. Clean all exterior surfaces of the cabinet. Do not use cleaners, steel wool, or any other
abrasive material on stainless steel.
C. Filter the cooking oil and replace if necessary. The oil should be filtered more frequently
when under heavy use.
6.1.2 Weekly
A. Completely drain the oil from the fryer into a metal stockpot of sufficient size to safely hold
the entire contents of the frypot for disposal. Do not use a glass or plastic container.
B. Clean the frypot by following boil-out procedures in Chapter 4.2 (operating thermostat/
Thermatron) or Chapter 6.2.1 (computer-equipped models).
WARNING
Never allow water to boil down and expose the frypot bottom. Frypot damage will
result.
6-1
Page 36
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 6: PREVENTATIVE MAINTENANCE
6.1.3 Periodic/Annual
This appliance should be inspected and adjusted periodically by qualified service personnel as part of a
regular kitchen maintenance program.
Frymaster/Dean recommends that this appliance be inspected at least annually by a Factory
Authorized Service Technician as follows:
• Inspect the cabinet inside and out, front and rear for excessive oil build-up and/or oil migration.
• Verify that the flue opening is not obstructed by debris or accumulations of solidified oil or shortening.
• Verify that burners and associated components (i.e. gas valves, pilot assemblies, ignitors, etc.) are in good
condition and functioning properly. Inspect all gas connections for leaks and verify that all connections
are properly tightened.
• Verify that the burner manifold pressure is in accordance with that specified on the appliance’s rating
plate.
• Verify that the temperature and high-limit probes are properly connected, tightened and functioning
properly, and that mounting hardware and probe guard are present and properly installed.
• Verify that component box components (i.e. computer/controller, transformers, relays, interface boards,
etc.) are in good condition and free from oil migration build-up and other debris. Inspect the component
box wiring and verify that connections are tight and that wiring is in good condition.
• Verify that all safety features (i.e. drain safety switches, reset switches, etc.) are present and functioning
properly.
• Verify that the frypot/cookpot is in good condition and free of leaks and that the frypot/cookpot insulation
is in serviceable condition. Verify that the frypot tube diffusers are present and in good condition (i.e. no
visible deterioration or damage).
• Verify that wiring harnesses and connections are tight and in good condition.
6.1.4 Stainless Steel Care
WARNING
DO NOT let water splash into the tank of hot oil. It will splatter and can cause severe
burns.
All stainless steel fryer cabinet parts should be wiped regularly with hot, soapy water during the day, and with
a liquid cleanser designed for stainless steel at the end of each day.
A. Do not use steel wool, abrasive cloths, cleansers or powders.
B. Do not use a metal knife, spatula or any other metal tool to scrape stainless steel! Scratches are
almost impossible to remove.
C. If it is necessary to scrape the stainless steel to remove any encrusted materials, soak the area first to
soften the deposit, then use a wood or nylon scraper only.
6-2
Page 37
is open and that gas is
Remove pilot gas supply line and check for dirt. Blow out with
Check that the lead from the thermocouple is tightly screwed
Remove end of thermocouple lead from pilotstat power unit
bushing and clean with fine sandpaper. Also check that
Pilot flame may be either too high or too low. Adjust flame by
Pilot flame of proper size but unstable. Flame wavers and
l times.
Check for drafts, which might be caused by air conditioning
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 7: TROUBLESHOOTING
DANGER
Hot cooking oil/shortening will cause severe burns. Never attempt to move this
appliance when filled with hot cooking oil/shortening or to transfer hot cooking
oil/shortening from one container to another.
DANGER
This equipment should be unplugged when servicing, except when electrical circuit
tests are required. Use extreme care when performing such tests.
This appliance may have more than one electrical power supply connection point.
Disconnect all power cords before servicing.
Inspection, testing and repair of electrical components should be performed by an
authorized service agent only.
7.1 PILOT BURNER MALFUNCTIONS
PROBLEM CORRECTIVE ACTION
Pilot will not ignite; no
evidence of gas at pilot
burner.
Pilot burner ignites but
will not remain lit when
gas knob is released.
1. Ensure the combination gas valve
available at the control.
2.
compressed air if necessary, then reinstall.
3. Check pilot burner orifice for dirt.
1.
into the pilotstat power bushing on the gas control.
2.
bushing is clean.
3. Thermocouple possibly defective; replace.
4.
turning pilot flow adjustment.
5.
does not envelop the thermocouple completely at al
equipment or make-up air apparatus. Turn air units off and recheck the pilot.
7-1
Page 38
Pilot flame may be adjusted too low, even though it appears to
Pilot flame may be adjusted too high and is on the verge of
With the exhaust blower in operation, the extra air causes the
Move actuating lever at switch to ensure it is not dragging in
the slots (use long tool to avoid burns). If so, bend the arm
carefully to clear the obstruction. Check the sail switch for
Cooked product or other material may have fallen into the flue
and lodged in the blower wheel, preventing it from turning.
nd shut off on thermal
overload. This condition will correct itself when motor cools
(20 minutes). If problems with blower overheating persist, call
If fryer is equipped with a Thermatron Controller, the
board may be defective.
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 7: TROUBLESHOOTING
7.1 PILOT BURNER MALFUNCTIONS (cont.)
PROBLEM CORRECTIVE ACTION
Pilot burner ignites
properly and burns
properly, but goes out
when the exhaust
blower comes on.
1.
be satisfactory. Re-adjust higher as described earlier.
2.
blowing out. Re-adjust lower.
3.
pilot to blow out. Re-adjust lower.
7.2 MAIN BURNER MALFUNCTIONS
PROBLEM CORRECTIVE ACTION
Main burner will not
come on even though
air blower is in
operation; no gas
pressure at main
burner.
1. Check that the combination gas valve is open.
2. Check that the pilot is lit and is operating properly.
3. The gas control may be defective; replace if necessary.
4. Check high temperature safety switch. Replace if defective.
5. Check sail switch as follows:
continuity and replace if defective.
Air blower is not
operating, although
power is present at the
fryer.
1.
Clean out flue and blower wheel.
2. Blower motor may have overheated a
for service.
3.
temperature probe or the Thermatron
Call for service.
7-2
Page 39
s pressure at the
gauge manometer. With the burner in operation, the pressure
should be about 10 mbar on natural and 27.5 mbar on propane
ator
adjustment and turn the adjusting screw clockwise to increase
gas pressure (or counterclockwise to decrease the pressure).
calibrate in accordance with instructions packaged with
Check probe adjustment. Probe should be 1/8" or less to
Cooking oil/shortening of inferior quality or used too long.
May be a short circuit in
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 7: TROUBLESHOOTING
7.2 MAIN BURNER MALFUNCTIONS (cont.)
PROBLEM CORRECTIVE ACTION
Main burner flames are
small and appear lazy;
1. Authorized Service Agent Only: Check ga
pressure tap of the gas control. Use a standard water-type U-
Frying compound does
not come up to
gases. If not, unscrew the cover of the pressure regul
temperature quickly.
Replace cover and plug.
Signs of excessive fry
vessel temperature;
Oil/shortening quickly
becomes discolored.
1. Check operating thermostat; may be out of calibration. Re-
thermostat.
2.
bottom of frypot (see illustration on page 4-1)
3. Authorized Service Agent Only: Check gas pressure.
4.
Replace with quality oil/shortening.
5. Authorized Service Agent Only:
system. Check wiring.
7.3 THERMATRON CALIBRATION
If the Thermatron controller requires adjustment, do the following:
1. Set Thermatron controller dial to the desired shortening temperature and wait for the shortening
temperature to stabilize.
2. When shortening temperature reaches setpoint (burners will cycle on and off, indicating setpoint
temperature has been reached), check the temperature with a high-quality immersion
thermometer.
3. Loosen the knob setscrew and rotate the knob to the correct temperature setting on the
Thermatron faceplate.
4. Check the temperature again with a high-quality immersion thermometer to confirm that the
setting is correct.
5. Re-tighten the knob setscrew at the calibrated position.
7-3
Page 40
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 7: TROUBLESHOOTING
7.4 WIRING DIAGRAMS
Note: The diagrams in this section depict wiring as of the date of manual publication.
It may not reflect design changes made to the equipment after publication. Refer to
the wiring diagram affixed to the unit when actually troubleshooting this equipment.
7.4.1 24G Series With Thermatron
PN 807-3746
Air Prover Switch
Drain Valve
24VAC Relay
PN 807-3611
Gas Valve
24 VAC/50 Hz
PN 807-2091
G31 Propane (LP)
G20, G25 Nat Gas
PN 807-2104
Safety Switch
Relay
24VAC
PN 807-3611
Valve Adaptor
PN 807-2127
Assembly
ECO Connector
Threaded to Valve
PN 2650
Hi-Limit Thermostat
Piezo Ignitor
PN 810-1001
PN 807-3560
Lead Wire
Electrode
PN 807-3650
Thermocouple
PN 807-3540
PN 810-1152
Solder Connection
230 VAC
24VAC to Oil
Return Circuit
SPST
PN 807-2196
Power Switch
PN 2653
Blower Motor
5 Amp Fuse
PN 807-3798
Transformer
7-4
PN 807-1999
Face Plate
PN 820-0135
POT
807-3536
Knob
PN 816-0534
24V
G.O.
PN 2442
Controller
Solid State
(Amp)
2 Pin Connector
PN 106-1900SP
Temp Sensor Probe
Page 41
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 7: TROUBLESHOOTING
7.4.2 24G Series With Computer
NC
Switch
Air Prover
Piezo Ignitor
PN 810-1001
Gas Valve
WHT
BLU
Valve Adaptor
24VAC/50HZ
Lead Wire
Threaded to valve
Electrode
Thermocouple
G31 LP Gas
PN 807-3628
PN 807-3552
G20, G25 Nat Gas
NO
WHT
BLU
24VAC
Relay, DPDT
PN 807-3611
BRN
246
135
BLU
BRN
PUR
PUR
24VAC
PN 807-3611
246
135
RED
BRN
BLK#2
PUR
8
7
BLU
BLU
PUR
8
7
Relay, DPDT
WHT
ECO Connector
BRN
WHT
Assy
Hi-Limit
Thermostat
Solder
Connection
Drain
1
2
1
2
BLU
BRN
Microswitch
PN 807-2104
BRN
230VAC
BLK
WHT
GRN
REDWHT
Motor
Blower
WHT#2
Fuse Holder
5 Amp
Motor
Fuse
BLK#2
5 Amp
WHT
WHT
WHT
WHT#2
BLK#2
BRN
230V
230V
Transformer
PN 807-1999
PN 807-0979
Transformer
YEL#2
12V
YEL#2
24V
Circuit
To Oil Return
7-5
YEL#2
129
11
10
YEL#2
8
BLU
5
RED
3 4 6 7
2
RED
RED
1
WHT
WHT
RED
WHT
Temp Probe
PN 807-1108
129
11
10
8
5
3 4 6 7
2
1
J2
Computer
GND
To Interface Board
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
13 14 15
129
11
10
8
Computer
Interface Board
5
3 4 6 7
2
1
To Computer
Page 42
24G SERIES FLATBOTTOM GAS FRYERS (CE)
CHAPTER 7: TROUBLESHOOTING
7.5 RECOMMENDED SPARE PARTS
Commonly replaced parts in older 24G Flatbottom Series gas fryers are:
Gas Valve- G20/G25- 807-2091
Gas Valve- G31- 807-2127
High-Limit Thermostat- 807-3560
Thermocouple- 810-1152
Temperature Sensor Probe- 106-0882SP
Thermatron Board- 807-3722
Power Switch- 807-3574
Boil-Out Switch (6-Terminal)- 807-3579
Fryer Reset Switch (Momentary)- 807-3576
Manual Filter Power Switch- 807-3580
Blower Motor- 2653-1
Sail Switch- 826-1773
Ignition Module- 807-3554
Ignitor Assembly- 106-1643SP
Ignition Cable- 106-1644SP
Sense Wire- 106-1645SP
7-6
Page 43
THIS PAGE INTENTIONALLY LEFT BLANK
Page 44
Dean, 8700 Line Avenue, PO Box 51000, Shreveport, Louisiana 71135-1000
Shipping Address: 8700 Line Avenue, Shreveport, Louisiana 71106
TEL 1-318-865-1711 FAX (Parts) 1-318-219-7140 FAX (Tech Support) 1-318-219-7135
PRINTED IN THE UNITED STATES
SERVICE HOTLINE
1-318-865-1711
Price: $10.00
819-5705
JUNE 2002
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