Frymaster 24G User Manual

24G Series Flatbottom Gas Fryers

Installation & Operation Manual

Models 1824G & 2424G

Dean, a member of the Commercial Food Equipment Service Association, recommends using
CFESA Certified Technicians.

24-Hour Service Hotline [phone] DECEMBER 2003

PRINTED IN THE USA

NON-CE &

*8196000*

*8196000*

*8196000**8196000*

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.

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. See NATIONAL CODE

REQUIREMENTS in Chapter 3 of this manual for specifics.

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

IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART FOR THIS ENODI S

EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART PURCHASED

DIRECTLY FROM FRYMASTER/DEAN, OR ANY OF ITS AUTHORIZED SERVICE CENTERS,

AND/OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL CONFIGURATION, THIS

WARRANTY WILL BE VOID. FURTHER, FRYMASTER/DEAN AND ITS AFFILIATES WILL NOT BE

LIABLE FOR ANY CLAIMS, DAMAGES OR EXPENSES INCURRED BY THE CUSTOMER WHICH

ARISE DIRECTLY OR INDIRECTLY, IN WHOLE OR IN PART, DUE TO THE INSTALLATION OF

ANY MODIFIED PART AND/OR PART RECEIVED FROM AN UNAUTHORIZED SERVICE CENTER.

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.

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.

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 cooking appliance.

DANGER

Instructions explaining procedures to be followed MUST

the event the operator detects a gas leak. This information can be obtained from the local gas

company or gas supplier.

MUST be posted in a prominent location in

MUSTMUST

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

IMPORTANT

IMPORTANTIMPORTANT

Safe and satisfactory operation of Dean equipment depends upon its proper installation.

Installation MUST

MUST conform with local codes, or in the absence of local codes, to National or

MUSTMUST

European Community (CE) Standards.

24G Series Flatbottom Gas Fryers

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

24G Series Flatbottom Gas Fryers

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 4-5

4.3 Final Preparation 4-7

5. CONTROLLER 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 Controller Calibration 7-3

7.4 Recommended Spare Parts 7-4

24G SERIES FLATBOTTOM GAS FRYERS

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 all EU countries.

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 addres s
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 [phone] 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

24G SERIES FLATBOTTOM GAS FRYERS

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

CAUTION boxes contain information about actions or conditions that may cause or result in a
malfunction of your system.

WARNING

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.

DANGER

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.

1.5 Service Personnel

1.5.1 Definitions

A. Qualified and/or Authorized Operating Personnel

1. Qualified/authorized operating personnel are those who have carefull y 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.

B. Qualified Installation Personnel

1. Qualified installation personnel are individuals, or firms, corporations, or companies, which,
either in person or through a representative are engaged in and are responsible for the
installation of gas-fired appliances. Qualified personnel must be experienced in such work,
be familiar with all gas precautions involved, and have complied with all requirements of
applicable national and local codes.

1-2

24G SERIES FLATBOTTOM GAS FRYERS

CHAPTER 1: INTRODUCTION

1.5.1 Definitions (cont.)

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

24G SERIES FLATBOTTOM GAS FRYERS
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 fr yer(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 servi ce this equipment will void the Dean warranty
and may result in damage to the equipment or injury to personnel.

2-1

24G SERIES FLATBOTTOM GAS FRYERS
CHAPTER 2: IMPORTANT INFORMATION

2.2 General (cont.)

Where conflicts exist betw een instructions and information in this manua l 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 accessori es packed inside the fr ypot. All units are adjusted,
tested, and inspected at the factory prior to crating for shipment.

Base units described below are designed for use i n a commercial food preparation environment aft er
installation as outlined in this manual.

MODEL 1824G 2424G

FRYING VESSEL
Frying Area:

Oil Capacity:

ENERGY REQUIREMENTS:
Gas [Natural or Propane (G20/25 & G31)]:
Electrical, Non-CE:
Electrical, CE:

APPROXIMATE SHIPPING WEIGHT
(lb):
(kg):

18 x 24 inches
(45.7 x 61 cm)
45-70 lb
(23-35 kg)

120,000 BTU/Hr (30,7 kcal; 35,1 kW)
115V/60~1Ø
230V/50~1Ø

285
129

24 x 24 inches
(61 x 61 cm)
65-90 lb
(33-45 kg)

300
138

2-2

24G SERIES FLATBOTTOM GAS FRYERS
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 equipped with painted cabinetry or optional stainless steel. Base units come
equipped with 6-inch (15-cm) adjustable legs or optional 5-inch (13-cm) casters. Multiple units
come equipped with casters.

Dean 24G Series Flatbottom gas fryers come standard with an electronic thermostat for reliable
temperature control. Fryers can be ordered with boil-out feature (optional- available only with
electronic thermostat controller).

A draft inducer draws air over the burners for combustion. Air movement directs the combustion
products back and forth across the fr ypot 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 solenoid­actuated gas valve.

• Combination safety gas valve includes built-in pressure regulator and pilot safety.

• Air prover 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, BTU/hr (kW/hr) of the burners, outlet gas pressure in
BTU/hr (kW/hr), and configuration: natural or propane gas. Rating plate data is essential for prop er
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, BTU/hr (kW/hr) of the burners, outlet gas pressure in inches W.C.
(mbars) and whether the unit has natural or propane gas orifices.

Fryers MUST

MUST be connected ONLY to the gas-type identified on the attached rating

MUSTMUST

DANGER

plate.

2-3

24G SERIES FLATBOTTOM GAS FRYERS
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 120 VAC (Non-CE), or 230VAC (CE), 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 6-inch (15-cm) adjustable
legs or optional 5-inch (13-cm) casters;

3. Combustible construction with a minimum clearance of 6-inch (15 cm) side and 6-inch (15
cm) rear, and equipped with factor y-supplied 6-inch (15-cm) adjustable legs or optional 5­inch (13-cm) casters.

DANGER

Local building codes prohibit a fryer with its open tank of hot oil from being installed

beside an open flame of any type, including those of broilers and ranges.

2-4

24G SERIES FLATBOTTOM GAS FRYERS
CHAPTER 2: IMPORTANT INFORMATION

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. NON-CE INSTALLATION STANDARDS: Fryer installation must conform with local
codes, or in the absence of local codes, to the appropriate national standards as listed below:

a. U.S. installations must meet: b. Canadian installations must meet:

American National Standard Institute CAN 1-B149 Installation Codes
ANSI Z83.11 Canadian Gas Association
American Gas Association 55 Scarsdale Road
8501 E. Pleasant Valley Road Don Mills, ONT, M3B 2R3
Cleveland, OH 44131

National Electrical Code Canadian Electric Code c22.1, part 1
ANSI/NFPA #70 Canadian Standards Association
American National Standard Institute 178 Rexdale Blvd.
1430 Broadway Rexdale, ONT, M9W 1R3
New York, NY 10018

NFPA Standards #96 and #211 c. Australian installations must meet:
National Fire Protection Association
470 Atlantic Avenue AS5601/AG601 Installation Codes
Boston, MA 02110 Standards Australia International
25 Raglan Street
South Melbourne, VIC 3205

2.6 Equipment Installed at High Altitudes

1. The fryer input rating [BTU/hr (kW/hr)] is for elevations up to 2,000 feet (610-m). For
elevations above 2,000 feet (610-m), the rating should be reduced 4-percent for each
additional 1,000 feet (305-m) above sea level.

2. The correct orifices are installed at the factor y if the operating altitude is known at the time
of the customer’s order.

2-5

24G SERIES FLATBOTTOM GAS FRYERS
CHAPTER 2: IMPORTANT INFORMATION

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 500-600°F (260-316°C). 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 500°F (260°C) 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 18 inches (45-cm)
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.

2-6