DEAN SM20G Installation Manual

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Super Marathon Series Gas Fryers
Installation & Operation Manual
Dean, a member of the Commercial Food Equipment Service Association, recommends using CFESA Certified Technicians.
24-Hour Service Hotline 1-800-551-8633
Price: $6.00
819-5649
08-98
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PLEASE READ ALL SECTIONS OF THIS MANUAL AND RETAIN FOR FUTURE
REFERENCE.
THIS PRODUCT HAS BEEN CERTIFIED AS COMMERCIAL COOKING EQUIPMENT
AND MUST BE INSTALLED BY PROFESSIONAL PERSONNEL AS SPECIFIED.
WE SUGGEST INSTALLATION, MAINTENANCE AND REPAIRS
SHOULD BE PERFORMED BY YOUR DEAN FACTORY
AUTHORIZED SERVICE AGENCY.
FOR YOUR SAFETY,
INSTRUCTIONS TO BE FOLLOWED IN CASE THE USER SMELLS GAS ARE TO
BE POSTED IN A PROMINENT LOCATION. THIS INFORMATION SHALL BE
OBTAINED BY CONTACTING THE LOCAL GAS COMPANY OR 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
GAS APPLIANCE.
IMPORTANT
SAFE AND SATISFACTORY OPERATION OF YOUR EQUIPMENT DEPENDS ON ITS PROPER INSTALLATION. INSTALLATION MUST CONFORM WITH LOCAL CODES, OR IN ABSENCE OF LOCAL CODES, WITH THE NATIONAL FUEL GAS CODE, ANSI Z223.1; THE NATURAL GAS INSTALLATION CODE, CAN/CGA­B149.1; OR THE PROPANE INSTALLATION CODE, CAN/CGA-B149.2.
WARNING!
IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE, OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATING AND MAINTENACE INSTRUCTIONS THROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.
On the Cover
SM-35 w/Optional Casters
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SUPER MARATHON SERIES
GAS FRYER
INSTALLATION AND OPERATION MANUAL
TABLE OF CONTENTS
PAGE
1. PARTS ORDERING AND SERVICE INFORMATION 2
2. IMPORTANT INFORMATION 3
3. INSTALLATION 5
4. DAILY OPERATION 12
5. CLEANING AND MAINTENANCE 14
6. FRYER TROUBLESHOOTING 15
7. A. APPENDIX A: FILTRATION A-1
COMPONENT LISTING AND INSTALLATION STANDARDS
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1. PARTS ORDERING AND SERVICE INFORMATION
1.1 ORDERING PARTS:
Customers may order parts directly from their local Authorized Parts Distributor. For this address and phone number, contact your Maintenance & Repair Center or call the factory. The factory address and phone number are on the cover of this manual.
To speed up your order, the following information is required:
Model Number Type Serial Number Type of Gas Item Part Number Quantity Needed
1.2 SERVICE INFORMATION:
Call the “800” number on the cover of this manual for the location of your nearest Maintenance & Repair Center or contact the factory direct. Always give the model and serial numbers of your filter and fryer.
To assist you more efficiently, the following information will be needed:
Model Number Type Serial Number Type of Gas
Nature of Problem Any other information which may be helpful in solving your service problem.
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2. IMPORTANT INFORMATION
2.1 DESCRIPTION: The Dean Super
Marathon gas fryers are energy-efficient, gas-fired units, design-certified by the International Approval Services (AGA/CGA), NSF International and manufactured to their basic performance and application specifications.
ahead of the fryer(s) for safety and ease of future service.
2. The Super Marathon gas fryers
have millivolt controls which do not require electrical power connections and do not have an ON/OFF switch on the control panel.
All units are shipped completely assembled with accessories packed inside the fryer vessel. All units are adjusted, tested and inspected at the factory before shipment. Sizes, weights and input rates of all models are listed in this manual.
NOTE: The on-site supervisor is responsible for ensuring that operators are made aware of inherent dangers of operating a deep fat fryer, particularly aspects of oil filtration, draining, and cleaning of the fryer.
2.2 RATING PLATE: This is attached to
the inside front door panel. Information provided includes the BTU/hr input of the burners, outlet gas pressure in inches WC and whether the unit has natural or propane gas orifices.
DANGER!
THE FRYER MUST BE CONNECTED ONLY TO THE TYPE OF GAS IDENTIFIED ON THE ATTACHED RATING PLATE.
2.3 PRE-INSTALLATION:
a. GENERAL: Only a licensed plumber
should install any gas-fired equipment.
1. A manual gas shut-off valve must
be installed in the gas supply line
b. CLEARANCES: The fryer area must
be kept free and clear of all combustibles. This unit is design­certified for the following installations:
1. Other than household use;
2. Non-combustible floor installation
equipped with factory-supplied 6” (15 cm) adjustable legs or 5” (13 cm) casters;
3. Combustible construction with a
minimum clearance of 6” (15 cm) side and 6” (15 cm) rear, and equipped with factory-supplied 6” (15 cm) adjustable legs or 5” (13 cm) casters.
c. U.S. installations must meet:
American National Standard Institute ANSI Z83.11 American Gas Association 8501 E. Pleasant Valley Road Cleveland, OH 44131
National Electrical Code ANSI/NFPA #70 American National Standard Institute 1430 Broadway New York, NY 10018
NFPA Standards #96 and #211 National Fire Protection Association 470 Atlantic Avenue Boston, MA 02110
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d. Canadian installations must meet:
Canadian Electric Code c22.1, part 1 Canadian Standards Association 178 Rexdale Blvd. Rexdale, ONT, M9W 1R3
CAN 1-B149 Installation Codes Canadian Gas Association 55 Scarsdale Road Don Mills, ONT, M3B 2R3
(427°C) and may damage or melt items stored over or behind the fryer.
d. Adequate distance must be maintained
from the flue outlet of the fryer(s) to the lower edge of the filter bank. NFPA Standard No. 96 states that “a minimum of 18 inches (45 cm)” should be maintained between the flue(s) and the lower edge of the exhaust hood filter.
e. COMPONENT LISTING AND
INSTALLATION STANDARDS: See Appendix B for a listing of various non-cooking components often supplied as a part of food service equipment and the applicable standards.
2.4 AIR SUPPLY & VENTILATION :
Keep the area around the fryer clear to prevent obstruction of combustion and ventilation air flow as well as for service and maintenance. Never use the interior of the fryer cabinet for storage.
a. A commercial, heavy-duty fryer must
vent its combustion wastes to the outside of the building. It is essential that a deep fat fryer be set under a powered exhaust hood or that an exhaust fan be provided in the wall above the unit, as exhaust gas temperatures are approximately 800­1000°F (427-538°C). Check air movement during installation. Strong exhaust fans in this hood or in the overall air conditioning system can produce slight air drafts in the room.
b. Do not place the fryer’s flue outlet
directly into the plenum of the hood, as it will affect the gas combustion of the fryer.
e. 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 ALTITUDE: The fryer input rating
(BTU/hr) is for elevations up to 2,000 feet (610 m). For elevations above 2,000 feet, the rating should be reduced four percent (4%) for each additional 1,000 feet (305 m) above sea level.
The correct orifices are installed at the
factory if operating altitude is known at time of the customer’s order.
2.6 RECEIVING AND UNPACKING:
Check that the container is upright. Use outward prying only—no hammering—to remove the carton. Check the fryer(s) for visible damage. If damage has occurred, do not refuse shipment, contact the freight company. Do not contact the factory.
Remove, unwrap, wash, and temporarily set aside any accessories shipped in the fryer vessel.
c. Do not store anything on shelving
over or behind the fryer. Exhaust temperatures can exceed 800°F
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3. INSTALLATION
NOT LEVEL, THE FRYER MAY TIP
3.1 POSITIONING:
a. Initial Installation: If the fryer is
installed with legs, do not push the fryer to adjust its position. Use a pallet or lift jack to lift the fryer slightly and place the fryer where it is to be installed.
b. Relocating The Fryer: Before
relocating a fryer installed with legs, remove all weight from each leg before moving.
If a leg becomes damaged during movement, contact your service agent for immediate repair/replacement of that leg.
CAUTION
THIS FRYER MAY TIP AND CAUSE PERSONAL INJURY IF NOT SECURED IN A STATIONARY POSITION. REMOVE ALL SHORTENING BEFORE MOVING FRYER AS IT MAY CAUSE SEVERE BURNS UPON CONTACT.
c. Insert the threaded leg screw into leg
support coupling.
INSTALLING LEG INTO
LEG SUPPORT ASSEMBLY
d. Turn the leg clockwise until the leg is
hand tight against the leg support assembly.
e. 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.
3.2 LEGS:
a. Install legs (or optional casters) near
where the fryer is to be used, as neither is secure for long transit. Unit cannot be curb mounted and must be equipped with the legs or casters provided.
b. After unpacking, use a pallet or lift jack
to raise the fryer about a foot before installing the legs.
HAND-TIGHTEN THE LEG
f. Proceed to Step 3.4, Leveling, to ensure
the fryer is level before using.
WARNING!
A FRYER MUST BE LEVEL BEFORE FILLING WITH OIL. IF THE FRYER IS
OVER AND MAY CAUSE INJURY TO THE OPERATOR.
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3.3 CASTERS:
LEG SUPPORT ASSEMBLY
NOT LEVEL, THE FRYER MAY TIP
a. Install casters near where the fryer is to
be used, as casters are not secure for long transit. The fryer cannot be curb mounted and must be equipped with either the legs or casters provided.
e. For fryers with casters, there are no
built-in leveling devices. The floor where the fryers are installed must be level.
b. After unpacking, use a pallet or lift jack
to raise the unit about a foot before installing the casters.
c. Insert the threaded caster screw into leg
support coupling. Grasp the base of the caster and tighten the caster by hand, turning clockwise, until snug against the leg support assembly.
INSTALLING CASTER INTO
d. Tighten the caster against the leg
support assembly by using a 3/4” open end wrench.
WARNING!
A FRYER MUST BE LEVEL BEFORE FILLING WITH OIL. IF THE FRYER IS
OVER AND MAY CAUSE INJURY TO THE OPERATOR.
3.4 LEVELING:
a. Place a carpenter’s spirit level across
the top of the fryer and level the unit both front-to-back and side-to-side. If it is not level, the unit may not function efficiently, the oil may not drain properly for filtering and in a line-up it may not match adjacent units.
b. Legs (Only):
1. If the floor is smooth and level,
level the unit by using the leg screw threads. Adjust to the high corner and measure with the spirit level. The legs have about one inch of adjustment thread.
TIGHTEN CASTER WITH 3/4” OPEN END WRENCH
2. Adjust leg height with an adjustable
or 3/4” open-end wrench.
ADJUST LEG HEIGHT WITH
AN ADJUSTABLE WRENCH
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3. When leveling the fryer, hold the
leg body firmly to keep the leg from rotating while turning the hex bullet foot.
c. If the floor is uneven or has a decided
slope, it is recommended to place the fryer on a a smooth platform. Do not rely on leg/caster thread adjustment.
CAUTION
LEG ADJUSTMENT MUST NOT EXCEED ONE INCH; THE UNIT WILL BECOME UNSTABLE AND TIPPING CAN OCCUR.
fryer uses a ¾” NPT inlet; however, the gas supply lines must be sized to accommodate all the gas-fired equipment that may be connected to that gas supply. Consult your contractor, gas company, supplier, or other knowledgeable authorities.
a. Manual shut-off valve: This gas
service supplier-installed valve must be installed in the gas service line ahead of the fryer in the gas stream and in a position where it can be reached quickly in the event of an emergency.
FRYERS MUST BE AT ROOM TEMPERATURE, EMPTY OF OIL, AND IF FITTED WITH LEGS, LIFTED DURING MOVEMENT TO AVOID DAMAGE AND POSSIBLE BODILY INJURY.
d. If the fryer is moved, re-level the fryer
following the instructions given in Step
3.4.
e. This fryer must be restrained to prevent
tipping when installed in order to avoid the splashing of hot liquid. The means of restraint may depend on the type of application, such as connecting to a battery of appliances or installing the fryer in an alcove, or by separate means, such as restraining devices. A bracket has been provided on the fryer back panel for this purpose.
The install must be reviewed at the time of installation to ensure it meets the intent of these instructions. The on-site supervisor and/or operator(s) should be made aware there is a restraint on the appliance and, if disconnection of the restraint is necessary, to reconnect this restraint after the appliance has been returned to its originally installed position.
CAUTION
THE FRYER MUST BE ISOLATED FROM THE GAS SUPPLY PIPING SYSTEM BY CLOSING ITS INDIVIDUAL, MANUAL SHUT-OFF VALVE DURING ANY PRESSURE TESTING OF THE GAS SUPPLY PIPING SYSTEM AT PRESSURES EQUAL TO OR LESS THAN ½ PSIG (3.45 KPa).
b. Pressure regulating:
1. External regulators are not
normally required on this fryer, as that function is performed by a safety control valve.
2. If the incoming pressure is in
excess of ½” PSIG (3.45 KPa), a step-down regulator will be required. Your local servicer should check the manifold pressure with a manometer.
3. Domestic Units: Units using
natural gas require 4” WC (10 mbar). Domestic propane units require 11” WC (27.4 mbar).
4. Export Units: Units using natural gas require 3.5” WC (8.7 mbar). Export propane units require 10” WC (25 mbar).
3.5 GAS CONNECTIONS: The gas
supply (service) line must be the same size or greater than the fryer inlet line. This
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NEW CONNECTION IS NOT ONLY
SOLUTION WILL FIND.
CAUTION
THE FRYER AND ITS INDIVIDUAL SHUT-OFF VALVE MUST BE DISCONNECTED FROM THE GAS SUPPLY PIPING SYSTEM DURING ANY PRESSURE TESTING OF THE GAS SUPPLY SYSTEM AT TEST PRESSURES IN EXCESS OF ½ PSIG (3.45 KPa).
c. Orifices: The fryer can be ordered to
operate on either natural or propane 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.
d. Rigid Connections: The fryer can be
connected singularly or as part of a cooking line. Check any installer­supplied intake pipe(s) visually and clean threading chips, or any other foreign matter before installing into a service line. If the intake pipes are not clear of all foreign matter, the orifices will clog when gas pressure is applied.
CAUTION
ALL CONNECTIONS MUST BE SEALED WITH A JOINT COMPOUND SUITABLE FOR LP GAS, AND ALL CONNECTIONS MUST BE TESTED WITH A SOAPY SOLUTION BEFORE LIGHTING ANY PILOTS.
2. If the unit is installed with casters, the installation should be made with a connector that complies with the Standard for Connectors for Moveable Gas Appliances, ANSI Z21.69 or Connectors for Moveable Gas Appliances, CAN/CGA-6.16, and a quick­disconnect device that complies with the Standard for Quick Disconnect Devices for Use with Gas Fuel, ANSI Z21.41, or Quick Disconnect for Use with Gas Fuel, CANI-6.9, adequate means must be provided to limit the movement of the appliance without depending on the connector and the quick disconnect device or its associated piping to limit the appliance movement. A restraining bracket is provided on the appliance structural back to prevent the unit from moving from its installed position.
3.6 ELECTRICAL CONNECTIONS:
The wiring diagram is attached to the inside of the fryer door. The diagram can also be found on page 16, Chapter 6, Troubleshooting. The fryer is equipped with a millivolt control system which does not need an outside power source.
WARNING
PUTTING AN OPEN FLAME BESIDE A
e. Flexible Couplings & Connectors:
1. If the fryer is installed with
couplings or quick disconnect fittings, the installer must use a heavy-duty, AGA design-certified commercial connector of at least ¾” NPT (with suitable strain relief) in compliance with ANSI Z-21.69-
1979. Domestic connectors are not suitable.
DANGEROUS, BUT WILL OFTEN MISS SMALL LEAKS THAT A SOAPY
3.7 INITIAL START-UP:
a. 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. Wash thoroughly with hot, soapy water to remove any film
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residue and dust or debris before food
Pilot
preparation, then rinse out and wipe dry. Wash also any accessories shipped with the unit. Close the drain­valve completely and remove the crumb screen. Make sure the screws holding the thermostat and limit control sensing bulbs into the vessel are tight.
Drain Shut-Off Valve
b. INITIAL PILOT LIGHT: All Dean
Industries’ fryers are tested, adjusted and calibrated to sea level conditions before leaving the factory. Adjustments to assure proper operation may be necessary on installation to meet local conditions, low gas pressure, differences in altitude, variations in gas characteristics, to correct possible problems caused by rough handling or vibration during shipment, and are to be performed only by qualified service personnel. These are the responsibilities of the customer and/or dealer and are not covered by Dean Industries’ warranty.
WARNING
WHEN LIGHTING PILOTS AND CHECKING FOR BURNER PERFORMANCE, DO NOT STAND WITH YOUR FACE CLOSE TO THE BURNERS…THEY MAY LIGHT WITH A “POP” AND COULD CAUSE FLASH BACK AND FACIAL BURNS.
2. Ensure that the following steps are done in sequence before lighting or re-lighting the pilot:
a) Turn off the manual shut-off
valve on the incoming service line.
b) Turn the operating thermostat
“OFF”.
c) Depress the pilot gas cock dial
on the safety control valve and turn “OFF”.
1. The inlet pipe at the lower rear of
the fryer brings incoming gas to the pilot safety control valve, then to the pilot and/or main burners. The pilot is located high in the cabinet center, at the base of the fryer vessel. It will require a long match or taper to light.
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Pilot Gas Cock Dial
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d) Wait at least 5 minutes for any
accumulated gas to disperse.
3. Fill fryer tank with liquid oil (or
water during testing) to the “oil level” line scribed into the rear wall of the tank.
4. Open the manual shut-off valve on
the incoming service line.
5. Apply a lighted match or taper to
the pilot burner head.
6. Turn the safety valve gas cock to
“Pilot”, depress and hold the dial until the pilot stays lit when the dial is released. This may take a minute or longer.
7. If the pilot does not stay lit,
depress the dial and re-light it, holding the dial in longer before releasing. It may be necessary to re-light the pilot several times until the lines are purged of any trapped air and a constant gas flow is attained.
8. When the pilot stays lit, turn the
gas cock dial to “ON”.
9. Turn the thermostat to any “ON”
setting and watch to make sure the main burner ignites from the pilot.
WARNING
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 SERVICE.
3.8 HEATING THE VESSEL: This
step will check main burner operation, initial thermostat calibration, and clean the vessel for initial food production.
a. Fill the fryer vessel with hot or cold
water to the oil level line scribed in the back of the tank.
b. Set the operating thermostat/
temperature controller dial to 220°F (104°C), just above that of boiling water.
c. The main burner will ignite. d. Reset the temperature controller to
200°F (93°C).
e. The burners should shut-off just as the
water starts to boil.
f. When satisfied that the burners and
thermostat are operating properly, drain the vessel of water and dry thoroughly. Refill it with shortening as directed below.
Operating Thermostat
3.9 FINAL PREPARATION:
a. When using a liquid shortening
(cooking oil), fill the fryer to the “oil level” line scribed into the back of the fryer vessel.
b. When using a solid shortening, either
melt it first, or cut into small pieces and tightly pack it below the heat tubes, between the heat tubes, and on top of the heat tubes, leaving no air
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spaces and being careful not to disturb the sensing bulbs. Make sure the crumb screen is removed before placing solid shortening in the fryer. Melt this shortening by turning the burners “ON” for about five or ten seconds, “OFF” for a minute, etc. until the shortening is melted. If you see any smoke coming from the oil while melting this way, shorten the “ON” cycle and lengthen the “OFF” cycle. Smoke shows that you are scorching the shortening and reducing its useful life.
WARNINGS
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.
NOTE: NEVER MELT A SOLID BLOCK OF SHORTENING BY SETTING IT WHOLE ON TOP OF THE HEATING TUBES. THIS IS UNSAFE, INEFFICIENT AND DANGEROUS.
c. When the fryer vessel is filled and the
shortening melted, place the crumb screen over the heat tubes.
d. Before starting operation, turn the
operating thermostat to the probable working temperature; wait for the temperature to stabilize then check with a high-quality immersion thermometer.
ALWAYS DRAIN HOT OIL INTO A METAL CONTAINER. HOT OIL CAN MELT PLASTIC BUCKETS AND CRACK GLASS CONTAINERS.
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4. DAILY OPERATION:
CAUSING SEVERE BURNS.
4.1 OPENING: At opening time, always
visually check the fryer for: a. The combination or main gas valve is
“OFF”.
b. To light the fryer, see Section 3-7.
4.2 GENERAL USE OF THE
FRYER:
a. For consistent quality product,
convenience and long-term savings, use a high-quality liquid frying compound.
b. If using solid shortening, never melt a
block of shortening by setting it on top of the heating tubes. This is dangerous and can easily cause the vessel heat tube to burn through, warp, or overstress the welded seams.
c. Although 350°F (177°C) is the
recommended temperature for most cooking operations, set the fryer at the lowest possible temperature which produces a high quality end product while ensuring maximum life of frying compound.
tubes, around the heat tubes, and on top of the heat tubes, leaving no air spaces around the heat tubes and being careful not to disturb the sensing bulbs. Melt this shortening by turning the burners “ON” for about five or ten seconds, “OFF” for a minute, etc. until the shortening is melted. If you see any smoke coming from the oil while melting this way, shorten the “ON” cycle and lengthen the “OFF” cycle. Smoke shows that you are scorching the shortening and reducing its useful life.
c. Turn the temperature controller to
350°F (177°C). In less than 30 minutes, the frying compound temperature will stabilize and be ready for production.
CAUTION
WHEN FILTERING, NEVER LEAVE THE FILTER UNATTENDED. THE ACTION OF THE OIL MOVING THROUGH THE LINES COULD KNOCK A FLEXIBLE RETURN HOSE OUT OF THE FRYER, SPRAYING HOT OIL AND
When the fryer is not in use, the thermostat should be set lower than that used during cooking. Light loads, too, may be cooked at lower temperatures. A good operator will experiment to determine the optimum temperature and load conditions for the various food items to be cooked.
4.3 TURN ON PROCEDURES:
a. If fryer is empty, pour enough frying
compound into the vessel to fill the vessel to the “oil level” line scribed on the rear wall.
b. When using a solid shortening, either
melt it first, or cut into small pieces and tightly pack it below the heat
4.4 FILTERING: Detailed operating and
troubleshooting information about Dean filtration systems can be found in Appendix A of this manual or in the operating manual provided with your filter unit.
a. The frying compound should be
filtered at least daily or even more frequently if cooking is heavy. This ensures the longest life possible for the frying compound, gives better taste to the food being prepared and minimizes flavors being transferred from batch to batch.
b. When completing a filter cycle, always
close the return valve(s) at the fryer(s)
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to avoid siphoning oil out of the fryer into the filter and open the valve at the filter to promote draining of the return lines into the filter pan.
c. If using solid shortening, always make
sure the return lines are clear before turning off the filter motor and hang any flexible lines up to drain. Solid shortening will solidify as it cools, eventually clogging the lines.
4.5 CLOSING:
a. When closing at night, filter the oil in
all fryers and drain the filter lines.
b. Cover the open tanks of oil. c. Turn the control knob on the
combination gas valve “OFF”.
d. Turn filter power switch “OFF”.
4.6 SHUT-DOWN: When closing down
for periods longer than overnight, a. Drain the frying compound and clean
the vessel thoroughly.
b. Either discard the frying compound or
return it filtered to the vessel and then cover it.
c. Non-stainless Fry Vessels Only: If
frying compound is discarded, lightly coat the inside of the non-stainless vessels with fresh frying compound to prevent rusting of the bare mild steel frying vessels.
d. Turn the control knob on the
combination gas valve “OFF”.
e. Turn the manual valve on the
incoming gas service line to “OFF”.
f. Disconnect any 120-volt power cords
for the filter units from the wall sockets.
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5. CLEANING & MAINTENANCE
DO NOT LET WATER SPLASH INTO THE
TANK OF HOT OIL. IT WILL SPLATTER
DAMAGE AND PERSONAL INJURY.
DO NOT DRAIN WATER INTO FILTER. WATER WILL DAMAGE THE FILTER PUMP.
WARNING!
IF THE FRYER IS NOT COMPLETELY EMPTY OF OIL, ADJUSTMENTS, ALTERATIONS, SERVICE OR MAINTENANCE CAN CAUSE PROPERTY
5.1 GENERAL: Any piece of equipment
works better and lasts longer when maintained properly and kept clean. Keep the fryer must be kept clean during the working day. Clean the fryer at the end of each day.
5.2 DAILY: Wash all removable parts. Clean
all exterior surfaces of the body. Do not use cleansers, steel wool, or any other abrasive material on stainless steel. Filter the cooking oil and replace if necessary. The oil should be filtered more often than daily under heavy use conditions.
5.3 WEEKLY:
f. Refill with clear water, set operating
thermostat to 220°F (104°C), and boil again. Once boiling is completed, turn operating thermostat “OFF”, drain, rinse, and dry thoroughly.
CAUTION
DO NOT LET WATER BOIL DOWN TO THE POINT THAT TUBES ARE EXPOSED AS THIS WILL DAMAGE THEM.
g. Immediately refill with cooking oil or
frying compound as directed in Section
4.3.
WARNING!
AND CAN CAUSE SEVERE BURNS.
a. Completely drain the oil from the fry
vessel into either the filter or a steel container. Do not use a plastic bucket or glass container.
b. Clean the vessel with a good grade of
cleaner or hot water and a strong detergent.
c. Close the drain valve and refill with
either the cleaning solution or water and detergent.
d. Set operating thermostat to 220°F
(104°C). Bring to a rolling boil, then turn the heat down and let the mixture stand until deposits and/or carbon spots can be removed with the Teflon brush.
e. Scrub tank walls, bottom and heating
tubes. Then drain vessel and rinse in clear water.
5.4 PERIODIC: The fryer should be checked
and adjusted periodically by qualified service personnel as part of a regular kitchen maintenance program.
5.5 STAINLESS STEEL: All stainless steel
fryer body parts should be wiped regularly with hot, soapy water during the day and with a liquid cleaner designed for this material 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 loosen the material, then use a wood or nylon scraper only.
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6. TROUBLESHOOTING
6.1 PROCEDURES: The problems and possible solutions given in this section cover those most
commonly encountered. To troubleshoot, perform the test set-up at the beginning of each condition. Follow each step in sequence as shown in the troubleshooting flowcharts.
6.2 SET-UP: Follow start-up procedures found in Section 3.7, Initial Start-Up, on page 8 of this
manual. Attempt to light the pilot and then follow the flowchart below.
6.3 PILOT FAILS TO LIGHT:
1. Check to see that gas lines are
connected.
2. Re-light pilot. When attempting to
Pilot fails to light.
re-light the pilot, ensure combination gas valve manual knob is depressed for at least one minute. If pilot doesn’t light, go to step 3.
3. Call for service.
6.4 FRYER FAILS TO HEAT:
1. Check to ensure gas valve is set to
the “ON” position.
2. Set operating thermostat to 350°F
Fryer fails to heat fry vessel.
(177°C) and observe fryer. Do the main burners come on and heat the fry vessel? If no, go to step 3.
3. Call for service.
FOR DETAILED TROUBLESHOOTING AND SERVICE-RELATED INFORMATION, CALL THE DEAN SERVICE HOTLINE AT 1-800-551-8633.
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6.5 MILLIVOLT WIRING DIAGRAM:
White
Combination Gas
Valve
Red
Thermopile
Red
Red
Hi-Limit
6.6 FRYER SPECIFICATIONS:
SM 20 SM 35 SM 50
Frying Vessel: Frying Area: Oil Capacity: Energy Requirements: Gas (Nat Gas or LP): BTU/hr: Overall Height: Working Height: Overall Width:
Overall Depth: Shipping Weight:
6 ½” x 14”
20 – 23 lbs.
Natural or Propane
50,000 BTU/hr
7.75” (one vessel)
15.0” (two vessels)
115 lbs. 180 lbs. 180 lbs.
Operating Thermostat
Black
Black
14” x 14”
35 – 43 lbs.
Natural or Propane
90,000 BTU/hr
45.0” 45.0” 45.0”
35.0” 35.0” 35.0”
15.50” 15.50”
29.25” 29.25” 29.25”
14” x 14”
35 – 50 lbs.
Natural or Propane
115,000 BTU/hr
Frying Vessel: Frying Area: Oil Capacity: Energy Requirements: Gas (Nat Gas or LP): BTU/hr: Overall Height: Working Height: Overall Width: Overall Depth: Shipping Weight:
SM 60 SM 80
18” x 18”
60 – 75 lbs.
Natural or Propane
150,000 BTU/hr
45.0” 45.0”
35.0” 35.0”
20.0” 21.0”
35.50” 35.50”
255 lbs. 260 lbs.
16
Natural or Propane
165,000 BTU/hr
20” x 20”
80 – 100 lbs.
Page 18
7. COMPONENT LISTING AND INSTALLATION STANDARDS
The following is a selection of listing and installation standards applicable to non-cooking components often supplied as part of food service equipment. The selection is not intended to be complete and other nationally recognized standards may be appropriate. This listing was current as of the revision date shown on the cover of this manual.
LISTING
COMPONENT
Grease Extractor ANSI/UL 710-1990 ANSI/NFPA 96-1991 Power Ventilators ANSI/UL 705-1984 ANSI/NFPA 96-1987
Filter Unit
Fire Ext. (CO2)
Fire Ext. (Dry Chemical)
Fire Ext. (Water) Fire Ext. (Foam) ANSI/NFPA 11-1988
Automatic Sprinklers ANSI/UL 199-1990 ANSI/MFPA 13-1989 Smoke Detectors
Heat Detectors for Fire Protective Signaling Devices
STANDARD
ANSI/UL 900-1987 ANSI/UL 586-1990 ANSI/UL 154-1990
CAN/ULC-S503-M90
ANSI/UL 299-1990
CAN/ULC-S504-M89
ANSI/US 626-1990
CAN4-S507-M83
ANSI/UL 521-1988
CAN/ULC-S530-1978
ANSI/UL 521-1988
ULC-S530-1978
INSTALLATION
STANDARD
ANSI/NFPA 96-1987 ANSI/NFPA 96-1987
ANSI/NFPA 12-1989
ANSI/NFPA 17-1990
ANSI/MFPA 13-1989
ANSI/NFPA 72B-1986
ANSI/NFPA 72B-1986
17
Page 19
APPENDIX A
CAUSING SEVERE BURNS.
Filter Pan Bottom
FILTRATION INSTRUCTIONS
1. GENERAL:
a. These instructions are not intended to
replace the operating instructions that came with your Dean Filter System. They are intended to provide general information about filtration procedures and serve as a quick reference guide.
b. For consistent product quality,
convenience and long-term savings, use a high-quality liquid frying compound.
c. The frying compound should be
filtered at least daily or even more frequently if cooking is heavy. This ensures the longest life possible for the frying compound, gives better taste to the food being prepared, and minimizes flavors being transferred from batch to batch.
2. FILTER PREPARATION:
a. Turn the fryer “OFF”. b. Remove the filter pan assembly
from the cabinet.
Hold Down Ring Filter Papers (2)
Support Grid
d. When completing a filter cycle,
always close the return valve(s) at the fryer(s) to avoid siphoning oil out of the fryer into the filter and open the valve at the filter to promote draining of the return lines into the filter pan.
e. If using solid shortening, always
make sure the return lines are clear before turning off the filter motor and hang any flexible lines up to drain. Solid shortening will solidify as it cools and clog the lines.
CAUTION
WHEN FILTERING, NEVER LEAVE THE FILTER UNATTENDED. OIL MOVING THROUGH THE LINES COULD KNOCK A FLEXIBLE RETURN HOSE OUT OF THE FILTER PAN, SPRAYING HOT OIL AND
Exploded View of a Filter Pan
Assembly
FIGURE A-1
c. Remove the filter pan cover. d. Remove the crumb screen (if
provided) and clean.
e. Remove the hold-down ring and
clean.
f. Examine the filter paper, if it is dark
or scuffed in appearance, discard it. Follow procedures listed in Section A.4 to change dirty filter paper.
g. Remove the filter support grid and
clean.
h. Remove the filter pan and clean with
hot water, then re-install. Make sure all residual water is removed and the
A-1
Page 20
filter pan is dry. Any remaining
Filter
Pump
Arrows show
flow.
FIGURE A-2
water will cause dangerous splattering of hot oil when filtering.
i. Re-install filter support grid. Place
two sheets of filter paper on top of the support grid. Push paper to the filter pan bottom with the hold-down ring. Latch the hold-down ring into place.
j. Then reinstall the crumb catcher (if
provided) inside the filter pan. Place the filter cover on top of filter pan and slide the filter back inside the fryer.
k. Reconnect oil return quick disconnect
lines (if installed on the fryer).
direction of oil
Drain Valve with Extension
Oil Return
Quick
Disconnect
3. NORMAL OPERATION:
Dean Filter Systems are designed to be used as either a portable unit or a built-in filter as part of a fryer/filter system. Portable means that it can be moved from fryer to fryer.
The primary difference between filter systems is how the filtered oil is returned to the fryer vessel. Built-in systems have an internally-plumbed oil return line running from the filter’s quick disconnect to a special port in the fryer vessel’s rear wall where oil re-enters the fryer vessel. Portable systems return the filtered oil by means of a flexible oil return hose which connects to the filter’s quick disconnect. The operator uses a wand connected to the end of the flexible oil return hose to direct filtered oil into the fryer vessel from above.
Filter operations always start with making sure the unit is properly plugged in, then rolling the filter to the fryer to be filtered. The filter works directly under the fryer's drain valve.
Portable Filtration System
2. Turn the filter switch to the “ON”
position on the filter control panel to begin pumping oil into fryer. If your filter unit is equipped with a flexible hose/nozzle, ensure nozzle is positioned to return oil safely into the fryer vessel.
3. When oil and fryer vessel are
clean, close the drain valve. It takes the filter approximately 5 to 7 minutes to pump all oil back into the fryer. Run the filter pump an additional 10-15 seconds after bubbles appear in oil to clear oil return lines.
4. Make sure the drain valve is fully
closed.
a. Portable Filter Operation:
1. Open the drain valve by pulling
the handle out. The oil will transfer from the fryer vessel to the filter pan.
A-2
Page 21
FIGURE A-4
Heater
Arrows show oil flow direction.
Tubes
Fryer Battery with Built-in Filter System *
Fry Vessel
Fryer Drain Valve Handle (Red)
Pump
Filter
b. Built-in Filter Operation:
Figure A-3 shows a simplified version of a built-in filtration system. Arrows show the direction of oil flow when filtering. Use the figure as a guide for locating key components on a fryer battery with a built-in filtration system.
Oil Return
Line
Quick Disconnect
FIGURE A-3
Hose Connect
Valve
Oil Return
Handle
(Yellow)
* Note: Only major components are
shown.
1. Turn fryer “OFF”.
2. Filter the oil from one fryer at a
time.
3. Scoop approximately 3 quarts of
oil from the fryer to be filtered and set aside.
4. Remove the drop-in grid
covering the heater tubes from the fryer vessel. Set aside the drop-in grid. See Figure A-4.
5. Stir the oil below the heat
transfer tubes with an “L­shaped” Teflon brush to loosen sediments.
Drop-in Grid in a SM20
6. Open the fryer cabinet door.
7. Open the fryer drain valve at the
fryer (either pull the red handle to that fryer or open the valve at that vessel) and continue to stir and brush down the sides of the vessel and heater tubes.
8. Open the hose connect valve (or
pull the yellow handle) at the fryer.
A-3
Page 22
NOTE: This completes the filtering of
(
in Fryer Cabinet)
Quick Disconnect
one fryer. To filter additional fryers in the same battery, repeat the process starting at step 3.b.1.
Complete the process with the following final steps.
Yellow Handle
Locations of Filtration System Handles
Red Handle
FIGURE A-5
9. Turn filter motor switch “ON”.
10. Pour the three quarts of oil (from
step 3.b.3) into the fry vessel corners to rinse out stubborn debris.
11. Push the red drain valve handle
or turn the pump motor “OFF” (as applicable).
12. Re-install the drop-in grid into
the fryer.
13. Once the drop-in grid is covered
with shortening, turn the fryer power switch “ON” and push the reset switch (if applicable).
14. When the oil in the fryer starts to
bubble, open the filter cabinet door, then lift the front of the filter pan and allow the bubbling to continue for approximately 10­15 seconds more. If it is blowing bubbles, air is moving through the lines and the lines cannot be plugged.
15. Turn the filter switch “OFF”.
16. Close the oil return valve (or
push in the yellow handle) to the fryer and close the fryer cabinet door.
Filter Switches
Oil Return Line
Red Filter
Handle
Inside Filter Cabinet
FIGURE A-6
17. Close the hose connect valve (or
push yellow handle) at the fryer. Then open the oil return line by turning the red handle at the filter. This drains the oil return line back into the filter pan and clears the lines.
18. Close the filter cabinet door.
NOTE: With the hose connect valve “closed” at the fryer and the filter oil return valve “open”, any oil left in the return lines will drain into the filter pan and not be trapped in the lines. These valves should be kept in these positions when not filtering.
4. CHANGING FILTER PAPER:
The top piece of filter paper should be discarded when it becomes dark or scuffed in appearance. Follow these procedures:
a. Before changing the paper, use the
flexible hose (with about one inch of oil remaining in the filter pan) to flush debris from the filter pan sides onto the paper.
A-4
Page 23
b. Return all oil to the fryer.
FIGURE A-7
c. Open the hold-down ring locking
latches and lift the ring out of the filter tank. Your unit will be equipped with one of the types shown in figure A-7.
the filter paper. Re-install the crumb catcher (if so equipped). Then replace the filter pan cover.
h. The unit is now ready for operation.
5. TROUBLESHOOTING: These
troubleshooting procedures must be carried out only by a Factory Authorized Service Center or a local service company specializing in hotel and restaurant cooking appliances.
Locking Latches
d. Roll both ends of the used (top) sheet
of paper in to the center, making sure no sediment falls out. Discard the top sheet. Temporarily remove the bottom sheet and set aside.
e. Remove and check the support grid for
cleanliness and scrub if necessary. Check the filter pan for cleanliness and scrub if necessary. Also check the drain ports at the bottom rear of the filter pan for sediment or blockages.
f. Replace the support grid, lay a new
filter sheet on the grid, then place the old bottom sheet on top of the new sheet. It is essential that two sheets of Dean filter papers are used; use of other than OEM parts will void the filter warranty.
The problems and possible solutions given in this section cover those most commonly encountered.
To troubleshoot, perform the test set-up at the beginning of each condition. Start at the top of the diagram. Arrows direct the troubleshooter through the sequence. Follow each step in sequence as shown in the troubleshooting diagrams.
Portable Filters – Begin on page A-6.
Built-in Filters – Begin on page A-7.
WARNING!
INSPECTION, TESTING, AND REPAIR OF GAS OR ELECTRICAL EQUIPMENT SHOULD BE PERFORMED BY QUALIFIED PERSONNEL.
Installing new filter paper.
FIGURE A-8
g. Replace the hold-down ring and latch
into position. Sprinkle 16oz of filter powder evenly across the surface of
DANGER!
USE EXTREME CARE DURING ELECTRICAL CIRCUIT TESTS. LIVE CIRCUIT WILL BE EXPOSED.
A-5
Page 24
Portable Filter Pump Fails to Pump Oil?
Filter Pump
fails to pump oil.
Does
your filter have a
heater?
Yes
Turn heater "ON"
and run heater
for 15 minutes.
Insert flexible oil return
hose into the filter pan
holster. Turn pump
motor "ON".
No
Does oil
flow?
Yes
No
Submerge hose into hot water (over
120°F/49°C). Keep both ends out of the water. If water gets into the
hose, the water will cause severe
splattering when hose is reconnected to the filter.
Once shortening has
softened, reconnect
the flexible oil return
hose to the filter.
Insert flexible oil return
hose into the filter pan
holster. Turn pump
motor "ON".
Disconnect flexible oil
return hose. Make sure it
is cool before handling.
Try blowing air through it.
No
Can you
blow air through
it?
Yes
Conduct normal
filter operations.
Yes No
Does oil
flow?
A-6
Blockage is between
the bottom of the filter
pan and the flex hose
valve. Go to page A-8.
Page 25
Filter Pump
fails to pump
oil.
Reset filter circuit
breaker.
If equipped with a
heater, turn heater ON
and run heater for 15
minutes.
Turn pump motor ON.
Built-in Filter Pump Fails to Pump Oil?
Does oil
flow?
Yes
Shortening had solidified in the
filter.
When filtering, use the heater
and run the pump for at least
an additional 15 seconds after
air bubbles appear in the fry
vessel.
Conduct normal
filter
operations.
No
Turn pump OFF. Reset
filter circuit breaker and
wall circuit breaker (if
necessary).
Turn pump ON. If it fails
to pump oil go to page
A-9 and follow Pump
Troubleshooting.
Pump motor is
clogged or
faulty.
Contact your
local authorized
service center.
If pump provides
suction, check for
blockages in the oil
lines.
Start by following
procedures on
page A-10.
If blockage is not in filter
pan or line from filter pan
to the pump, continue with
this flowchart procedure.
Disconnect oil
return line from the
pump to the fryer.
No
Submerge oil line into hot water
(over 120°F/49°C). Keep both ends out of the water. If water
gets into the line, the water will
cause severe splattering when
Can you
blow air through
it?
Yes
reconnected to the filter.
A-7
Once shortening has
softened, reconnect
oil line to filter.
Turn pump
motor ON.
Does oil
flow?
Yes
Conduct normal
filter
operations.
No
Contact your
local authorized
service center.
Page 26
Rate of oil
return to the fryer
is slowing.
Rate of Oil Return Slowing?
Is this the
first fryer to be filtered
during this filtering
session?
Yes
Check the filter
paper in the filter
pan.
Is the filter
paper properly secured
by the hold down
ring?
Yes
Paper may be
plugged by improper
use of filter powder.
Change the filter paper. Throw away the old top
sheet and use the old
bottom sheet as the new top
sheet.
Check the filter sump.
No
No
Sediment collects
around the suction pipe
in the filter bottom.
Paper may not be
secured by the hold down
ring. Air is being allowed
to get into the system.
Remove the filter
pan cover.
Unlatch hold-down ring and
remove the filter paper and
filter paper support grid.
Clean support grid
and set aside
temporarily.
Wipe sediments
out of the bottom
of the filter pan.
Inspect drain ports at the
bottom rear of the filter pan
and remove any sediment
or visible blockages.
Take a new sheet and
place it in the bottom of the pan. Place the new top sheet over it.
Secure the filter
papers by latching
the hold down ring.
Sprinkle 16oz of filter powder evenly across the surface of the filter paper.
A-8
Reassemble the filter
pan assembly. Turn
the pump motor "ON".
Has
the oil return rate
improved?
Yes
Conduct normal
filter operations.
Blockage may be
No
between the filter pan
bottom and the flex
Go to flowchart titled
"Blockage between
Filter Pan and Flex Hose
Valve" on page A-9.
hose valve.
Page 27
Blockage between Filter Pan and Flex Hose Valve?
Page 28
ENTER FROM PAGE A-7 OR A-8
HERE
Plug is in the bottom of
the filter pan or in the line
from the filter to the pump.
Disconnect the tubing from
the filter pan to the motor.
Make sure the pipe is cool.
Try blowing air
through it.
Can you
blow air through
it?
Yes
The line is clear. Reconnect hose
to the pump inlet.
Does oil
flow?
Yes
Conduct
normal filter
operations.
No
No
Soak the line in hot
water until you can
blow through it.
This line is clogged.
There may be a plug
in the bottom of the
filter pan.
Take filter pack apart, then scrub the bottom of the pan and clean the intake pipe to remove residual shortening.
Reassemble the filter
pack. Then turn pump
motor "ON".
Does oil flow?
Yes
Conduct normal filter
operations.
A-10
No
Go to page A-9 and
follow Pump
troubleshooting
procedures.
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