Frymaster SR38G Installation Manual

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Super Runner 38 Series Gas Fryers (CE)
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
819-5707
04-99
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danger
.
AUSTRALIA ONLY:
OIL TEMPERATURE
Keep the oil temperature in the fryer to a maximum of 190°C. Higher temperatures will cause rapid breakdown of the oil and give you no faster cooking.
At 205°C to 210°C the life of the oil is only one third of its life at 190°C. In addition, increased decomposition causes the oil o smoke badly even if the temperature is lowered to 190°C again.
High temperatures give you no advantage, cost you money and increase the fire
TEMPERATURA DELL?OLÍO
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THIS PRODUCT HAS BEEN CERTIFIED AS COMMERCIAL COOKING EQUIPMENT
IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE, OR
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!
MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATING AND MAINTENACE INSTRUCTIONS THROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.
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SUPER RUNNER 38 SERIES
GAS FRYER
INSTALLATION, OPERATION, & PARTS MANUAL
TABLE OF CONTENTS
PAGE
1. FACTORY PARTS ORDERING AND SERVICE 2
2. IMPORTANT INFORMATION 3
3. INSTALLATION 6
4. FRYER OPERATIONS 13
5. CLEANING AND MAINTENANCE 18
6. TROUBLESHOOTING 19
7.
1. FACTORY PARTS ORDERING & SERVICE
COMPONENT LISTING AND INSTALLATION STANDARDS
24
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 Dean Industries Service Hotline phone number is 1-800-551-8633 (US/Canada) or 1-318-865-1711 (Worldwide).
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 service hotline 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.
1.3 AFTER SALES:
In order to improve service, have the following chart filled in by the Dean Authorized Servicer who installed this equipment.
Authorized Servicer Address
Telephone/Fax Model # Serial # Type: Fryer Equipped For:
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2. IMPORTANT INFORMATION
being installed beside an open flame of
2.1 DESCRIPTION:
The Dean Super Runner gas fryers are energy-efficient, gas-fired units, design­certified by the International Approval Services (AGA/CGA), NSF International, Australian Gas Agency, Gaz de France and manufactured to their basic performance and application specifications.
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 kW/hr (BTU/hr) input of the burners, outlet gas pressure in millibars (inches WC) and whether the unit has natural or propane gas orifices.
1. A manual gas shut-off valve must be installed in the gas supply line ahead of the fryer(s) for safety and ease of future service.
2. The Dean CE Super Runner 38 gas fryers are millivolt systems and do not require an electric power supply for the fryers.
CAUTION
Local building codes usually prohibit a fryer with its open tank of hot oil from
any type, whether a broiler or the open burner of a range.
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;
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.
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.
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
e. CE/EXPORT STANDARDS: Fryer
installation must conform with local codes, or in the absence of local codes, with the appropriate national or European Community (CE) standards.
f. COMPONENT LISTING AND
INSTALLATION STANDARDS: See Chapter 7 for a listing of various non­cooking components often supplied as a part of food service equipment and the applicable standards.
2.4 ALTITUDE:
a. Do not connect this fryer to an exhaust
duct.
b. Correct installation and adjustment
will ensure adequate air flow to the fryer system. Proper input is 2m3 per hour per KW for gas supplied.
c. 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 the exhaust hood or in the overall air conditioning system can produce slight air drafts in the room.
d. 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.
a. GENERAL: The correct orifices are
installed at the factory if operating altitude is known at time of the customer’s order.
b. US (ONLY): The fryer input rating
(BTU/hr) is for elevations up to 2000 feet. For elevations above 2,000 feet, the rating should be reduced four percent (4%) for each additional 1000 feet above sea level.
c. CE/EXPORT: The fryer input rating
(in m3/hr) is for elevations up to 610 m. For elevations above 610m, the rating should be reduced four percent (4%) for each additional 305 m above sea level.
2.5 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.
e. Never use the interior of the fryer
cabinet for storage or store items on shelving over or behind the fryer. Exhaust temperatures can exceed 800°F (427ºC) and may damage or melt items stored in or near the fryer.
f. Adequate distance must be maintained
from the flue outlet of the fryer(s) to the lower edge of the filter bank. A minimum of 18"/45 cm should be maintained between the flue(s) and the lower edge of the exhaust hood filter.
g. 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.
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2.6 RECEIVING AND UNPACKING:
Temperature:
Check that the container is upright. Unpack the fryer carefully and remove all accessories from the carton. Do not discard or misplace these, as they will be needed.
After unpacking, immediately check the equipment for visible signs of shipping damage. If such damage has occurred, contact the carrier and file the appropriate freight claims. Do not contact the factory, as the responsibility of shipping damage is between the carrier and the dealer or end­user.
If your equipment arrives damaged:
a. File claim for damages immediately,
regardless of extent of damage.
b. 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.
0º Celsius = 32º Fahrenheit Temp. in degrees Celsius = (Temperature in
degrees Fahrenheit (F) – 32) X 0.555 100° Celsius = (212º Fahrenheit –32) X 0.555
c. Concealed loss or damage: If damage
is unnoticed until equipment is unpacked, notify freight company or carrier immediately, and file a concealed damage claim. This should be done within fifteen (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 Transit.
2.7 CONVERSION OF UNITS:
Pressure:
1 mbar = 10.2 mm water column (mm WC)
= 0.4 inch WC
20 mbar = 204 mm WC = 8 inch WC 1 Inch W.C = 25.4 mm WC = 2.5 mbar
Heat Input:
1 kW = 3410 BTU/hr 100 BTU/hr = 0.293 KW
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3. INSTALLATION
room temperature and drained of
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 the fryer as it may cause severe burns upon contact.
3.2 LEG AND CASTER INSTALLATION:
a. General:
1. Install legs and casters (optional) 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 (or legs and optional rigid casters) provided.
4. Proceed to Step 3.3, Leveling, after legs and/or optional rear rigid casters are installed to ensure the fryer is level before using.
b. Leg Installation:
1. Remove unit from pallet.
2. Carefully raise unit with forklift, pallet jack, or other steady means.
3. Insert hex head bolts (1/4-20 threads by 19mm (¾") long) from top of side panels and channels through bolt holes of leg mounting plates as shown in the Figure 3-1 on the next page.
4. Mount washer and lock nuts (1/4-20 threads Stover lock nut) from bottom of the leg mounting plates. The lock nut has a portion of threads deflected. Make sure the nut starts freely on the bolt like a common nut until the deflected thread portion is reached.
5. On the front door hinge corner, the bolts will be inserted first through the holes of the hinge plate, then followed with side panel, channel, and leg mounting plate.
6. Tighten the bolts and nuts with each bolt to 5.65 joules (50 inch-lbs.) minimum torque.
CAUTION
For caster retrofit, the unit must be at
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. If the optional rigid casters are to be installed on the fryer, the casters must be installed on the fryer rear channel assembly only.
shortening before installing the casters.
b. Installing Optional Rear Rigid Casters:
1. Install casters only at the rear of the unit as shown in the Figure 3-1.
2. Follow the same instructions for leg installations as given above in steps
3.2.b.1-6.
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NOT LEVEL, THE FRYER MAY TIP
Side Panel
Front Channel
Rear Channel
Side Panel
Structural Back
Front Door
Front Channel
1/4-20 HX HD Lock Nut
Front Leg w/Mounting Plate
P/N 2698
Adjust as needed.
Leg and Rigid Caster Installations
WARNING!
A FRYER MUST BE LEVEL BEFORE FILLING WITH OIL. IF THE FRYER IS
Caster Shims
(P/N 900-2949)
if required.
Washer P/N 1008
(P/N 2701)
Figure 3-1
19mm (1/4 - 20 x 3/4 in)
HX Bolt (P/N 1007)
Rear Rigid Caster
15.2 cm/6 in (P/N 2701)
2. Adjust leg height with an adjustable or 1-1/16” open end wrench by turning the hex bullet on the bottom of the leg.
3. The hex bullet is for minor leg
height adjustment only. Do not adjust more than 22mm (1").
OVER AND MAY CAUSE INJURY TO THE OPERATOR.
3.3 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 caster shims. Adjust to the high corner and measure with the spirit level.
ADJUST LEG HEIGHT WITH
AN ADJUSTABLE WRENCH
4. When leveling the unit, the leg body should be held firmly to keep the leg from rotating while turning the hex bullet foot to the required height.
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c. Rigid Casters (Only):
USING MORE THAN TWO SHIMS PER
1. Install the optional rigid casters on the fryer rear channel only.
necessary, to reconnect this restraint after the appliance has been returned to its originally installed position.
2. Do not use more than two metal shims per caster.
3. There are no thread adjustments for the rigid casters.
WARNING!
DO NOT USE MORE THAN TWO METAL SHIMS PER LEG/CASTER.
LEG/CASTER MAY CAUSE THE FRYER TO BECOME UNSTABLE, TIP OVER, AND MAY CAUSE INJURY TO THE OPERATOR.
d. If the floor is uneven or has a decided
slope, it is recommended to place the fryer on a smooth platform. Do not rely on leg thread or caster shims for adjustments.
e. If the fryer is moved, re-level the fryer
following the instructions given in Steps 3.3.a-c.
f. 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
NOTICE
If the fryer cannot be adjusted to perform correctly, or you have any questions about this install, contact your local authorized service agency.
3.4 GAS CATEGORIES:
The Dean Super Runner 38 Series Gas Fryers have obtained CE markings for countries and gas categories shown below:
Countries Supply Pressures
and Gas (mbar)
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
The
NL
Netherlands
PT Portugal
G20 20/25 I2E (R) B G31 37 I3P 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
II2H3P
II2ESI3P
II2H3P
II2H3P
II2H3P
II2E3P
II2L3P
II2H3P
3.5 GAS CONNECTIONS: The gas
supply (service) line must be the same size or greater than the fryer inlet line. This fryer is equipped with a 19 mm (3/4”) male ISO 7.1 inlet; however, the gas supply lines must be sized to
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accommodate all the gas-fired equipment
joint compound suitable for LP gas, and
pressures in excess of 3.45
KPa (½ PSIG).
that may be connected to that gas supply. Consult your contractor, gas company, supplier, or other knowledgeable authorities.
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.
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. This shut-off valve must be installed only by an authorized person to the requirements of the local gas authorities.
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 3.45 KPa (½ PSIG).
b. Pressure regulating:
1. External gas regulators are not
normally required on this fryer, as that function is performed by a safety control valve.
2. Australia: The following color codes are used to indicate the type of gas for which the fryer and components are to be used:
Gas Type Color Code
Natural Black Propane Orange
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
all connections must be tested with a soapy solution before lighting any pilots.
2. If the incoming pressure is in
excess of 3.45 KPa (½” PSIG), a step-down regulator will be required. Your local servicer should check the manifold pressure with a manometer.
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 piping system at test
c. Orifices:
1. The fryer can be ordered to operate on any available gas. The correct safety control valve, appropriate gas orifices, and pilot burner are
e. Flexible Couplings & Connectors:
1. General: A restraining bracket is provided on the structural back of the fryer to prevent the unit from moving from its installed position.
The fryer must be restrained by means independent of the flexible coupling or connector in order to limit the movement of the fryer.
2. US/Canada Standards: If the unit is to be installed with flexible couplings and/or quick disconnect fittings, the installer must use a heavy-duty, AGA design-certified commercial flexible connector of at least 3/4" (19mm) NPT (with suitable strain reliefs) in compliance
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with the Standards for Connectors
NEW CONNECTION IS NOT ONLY
for Movable Gas Appliances, ANSI Z21.69. Quick disconnect devices must comply with the Standard for Quick-Disconnect Devices for Use with Gas Fuel, ANSI Z21.41.
Domestic connectors are not suitable!
If the unit is to be installed with casters, flexible connectors must be used and the same ANSI standards mentioned on the previous page apply. Locking front casters are provided to limit the movement of the appliance without depending on the connectors or associated piping.
CAUTION
Any modification, adaptation, or gas conversion must be performed by qualified personnel only. Failure to use qualified personnel will void the Dean warranty.
3.7 ADJUSTMENTS / ADAPTATION TO DIFFERENT GASES:
a. Proper operation of appliances
requires operator to scrupulously respect the following adjustments in terms of:
1. gas inputs and pressures, air adjustment;
3. CE Standards: If the unit is to be installed with flexible coupling, use a commercial flexible coupling certified as NF D 36123 (or other national standard) or a quick disconnect device certified NF D 36124 (or other national standard).
f. Piping Sizes: According to the number
of fryers to be connected, the gas supply line must be sized as indicated in the chart below:
Number
of Fryers
Natural Gas
Propane Gas
(*) When exceeding 6 meters for a
configuration of more than 4 fryers, it is necessary to provide a 33mm (1 ¼”) rigid gas connection.
1 2 to 3
19mm
(3/4”)
13mm
(1/2”)
25mm
(1”)
19mm
(3/4”)
4 and
more (*)
33mm (1
¼”)
25mm
(1”)
2. voltage and polarities of electrical power supply.
b. Dean 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.
Failure to use qualified personnel will void the Dean warranty.
NOTICE
The installer is required to test the complete fryer operation prior to leaving the installation site.
3.8 GAS INPUTS:
a. Nominal Qn Heat Input is:
SR38G: 15 kW.
b. Inputs for different gases are as
follows:
WARNING
PUTTING AN OPEN FLAME BESIDE A
DANGEROUS, BUT WILL OFTEN MISS SMALL LEAKS THAT A SOAPY SOLUTION WILL FIND.
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G20
G25
G31 Propane
Natural Gas (Type H)
Natural Gas (Type L)
20 mbar : 1,58 M3/H
25 mbar: 1,84 M3/H
37 mbar: 1,16 KG/H
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3.9 CHART: ADJUSTMENT TO DIFFERENT GASES
GASES AND PRESSURES SUPPLY
G20
18 mbar
G25
25 mbar
G31
31 mbar
(1)
Diameter and markings of injectors
Burner Pilot TJ024 TJ024 TJ013 "red"
(2) Gas pressure at the regulator (mbar/inches WC)
Burner air adjustment No Air Adjustment No Air Adjustment No Air Adjustment
1.90 mm 1.90 mm 1.28 mm
"blue" marking "blue" marking "red" marking
12.0 mbar/5.00 in WC 17.5 mbar/7.03 in WC 22.0 mbar/8.83 in WC
NOTE: Outlet gas pressure must be controlled with precision 5 to 10 minutes after appliance is operating.
(1) – (2): For controls and adjustments, please refer to "gas valve" illustration. (Pilot : adjustment of flame’s volume may be achieved by turning the screw that is mounted on the gas
valve).
Adjust gas pressure to orifices by turning
the gas valve adjustment screw.
After adjustment, seal the screw.
WARNING!
CONVERTING A FRYER FROM ONE GAS TYPE TO ANOTHER SHOULD BE PERFORMED BY AUTHORIZED SERVICE PERSONNEL ONLY.
See Gas Valve diagrams on page 11.Change label "fryer equipped for" and
affix it to the rating plate. Erase gas that is not used.
c. Important : for the same gas:
3.10 STEPS TO FOLLOW DURING GAS CONVERSION (CE Only):
a. From G20 to G25:
No replacement of equipment.Adjust gas pressure to orifices by
turning the gas valve "adjustment screw".
After adjustment, seal the screw.See Gas Valve diagrams on page 11.
b. From G20 (or G25) to G31 propane (or
vice versa).
Replacement of burners orifices and
pilot.
G25 / 25 mbar or 20 mbarG31 / 37 mbarno change is to be executed on the
appliance.
d. When changing gas family – i.e changing
from natural gas to propane, please order the necessary kit as indicated hereafter. Specific gas conversion kit part numbers can be found at the bottom of the parts list found in Chapter 6.
This change can only be executed by a qualified and factory authorized personnel.
1. The complete kits for gas conversion include the following parts:
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SR38G Natural Gas to Propane Kit
1/8"
/ 3 mm
QTY REF DESCRIPTION
1 TJ013 Pilot injector 3 14-0067-59
1 Label
Appareil réglé pour : G31 / 37
Burner injector
(diam. 1.28 mm)
Fryer equipped for : G31/37
SR38G Propane to Natural Gas Kit
QTY REF DESCRIPTION
1 TJ024 Pilot injector 3 14-0067-49
1 Label
Fryer equipped for : G25 / 25 *
Burner injector
(diam. 1.90 mm)
Appareil réglé pour : G20 / 20
3.11 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.
Super Runner Gas
Valve, Burner, and
Orifice Locations
Super Runner Gas Valve
Adjustment
Figure 3-3
Inlet Pressure Tap
Figure 3-2
Outlet Pressure Tap 1/8 " / 3 mm
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4. FRYER OPERATIONS
CHECKING FOR BURNER
4.1 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 residue and dust or debris before food 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.
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.
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.
Drain Shut-Off Valve
WARNINGS!
DO NOT USE AN OPEN FLAME TO CHECK FOR THE PRESENCE OF GAS INSIDE THE FRYER CABINET.
IF PILOT FAILS TO LIGHT, WAIT 5 MINUTES BEFORE RELIGHTING TO ALLOW ANY ACCUMULATED GAS TO DISSIPATE.
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
Pilot
WARNING!
WHEN LIGHTING PILOTS AND
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:
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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”.
Pilot Gas Cock Dial
air and a constant gas flow is attained.
6. When the pilot stays lit, turn the
gas cock dial to “ON”.
7. Turn the thermostat to any “ON”
setting and watch to make sure the main burner ignites from the pilot.
Operating Thermostat
d) Wait at least 5 minutes for any
accumulated gas to disperse.
1. Fill fryer tank with liquid oil (or
water during testing) to the “oil level” line scribed into the rear wall of the tank.
2. Open the manual shut-off valve on
the incoming service line.
3. Apply a lighted match or taper to
the pilot burner head.
4. 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.
5. 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
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.
4.2 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 104°C (220°F), just above that of boiling water.
c. The main burner will ignite.
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d. Reset the temperature controller to
DANGEROUS.
93°C (200°F).
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.
4.3 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 with another appliance, 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 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.
c. When the fryer vessel is filled and the
shortening melted, place the crumb screen over the heat tubes.
DANGER!
NEVER MELT A SOLID BLOCK OF SHORTENING BY SETTING IT WHOLE ON TOP OF THE HEATING TUBES. THIS IS UNSAFE, INEFFICIENT AND
4.4 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 177°C (350°F) 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.
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.
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.
4.5 OPENING: At opening time, always
visually check the fryer for: a. The combination or main gas valve is
“OFF”.
b. Fry vessel is filled with liquid oil to
the oil level line scribed into the rear wall of the fry vessel tank.
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c. To light the fryer:
Operating Thermostat
1. Open the manual shut-off valve on the incoming service line.
2. Apply a lighted match or taper to the pilot burner head.
3. 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.
Pilot Gas Cock Dial
4. 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 hold the depress the pilot cock for several minutes or re-light the pilot several times until the lines are purged of any trapped air and a constant gas flow is attained.
5. When the pilot stays lit, turn the gas cock dial to “ON”.
6. Turn the thermostat to the desired cooking temperature and allow the fry vessel to heat for approximately 30 minutes before cooking. This will allow the fryer to stabilize the oil temperature at the desired setpoint which ensures quality cooking.
4.6 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 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
177°C (350°F). 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 causing severe burns.
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4.7 CHIP PRODUCTION RATE
(Australia):
Based on a recommended thermostat temperature setpoint of 177°C (350°F) and a cook time of 2.7 minutes, the production of 6 mm (1/4") cut frozen chips should be from 26.3 to 27.22 KG/hr (58 to 60 lbs/hr). Production rate will be influenced both by the moisture content of the chip, and the age/quality of the shortening used.
4.10 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.
4.8 FILTERING:
Detailed operating and troubleshooting information about Dean filtration systems can be found 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) 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. 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 the power cord for the
portable filter unit from the wall socket.
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.
4.9 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”.
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.
ALWAYS DRAIN HOT OIL INTO A METAL CONTAINER. HOT OIL CAN MELT PLASTIC BUCKETS AND CRACK GLASS CONTAINERS.
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5. CLEANING & MAINTENANCE
DO NOT LET WATER SPLASH INTO THE
TANK OF HOT OIL. IT WILL SPLATTER
ALTERATIONS, SERVICE OR
DO NOT DRAIN WATER INTO FILTER. WATER WILL DAMAGE THE FILTER PUMP.
WARNING!
IF THE FRYER IS NOT COMPLETELY EMPTY OF OIL, ADJUSTMENTS,
MAINTENANCE CAN CAUSE PROPERTY DAMAGE AND PERSONAL INJURY.
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.
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.
5.3 WEEKLY:
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 re-
Pilot fails to light.
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.
FOR DETAILED TROUBLESHOOTING AND SERVICE-RELATED INFORMATION, CALL THE DEAN SERVICE HOTLINE AT 1-800-551-8633 (US/Canada) or 1-318-865-1711 (Worldwide).
(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.
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6.5 MILLIVOLT WIRING DIAGRAMS:
6.5.1 US/Canada/CE:
White
Combination Gas
Valve
Red
Thermopile
Red
Red
Hi-Limit
6.5.2 Australia (Only):
Operating Thermostat
Black
Black
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6.6 EXPLODED PARTS DIAGRAM:
12
9
8
26
6
5
1
7
15
2
11
24
10
16
14-0684-2
14-0684-3
14-0684-3
14
18
20
3
17
19
37
4
30
36
13
28
35
21
33
25
31
22
21
23
29
A
29
B
TO ITEM 19
TO ITEM 19
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Page 24
6.7 SUPER RUNNER 38 GAS PARTS LIST: Item No. Description Dean P/N
1 Flue Assembly 12203 2
3 4 Front and Rear Channel 12-0373
5
6 Probe Retainer Top 18-0091 7 Grid Assembly 12081 8 Basket Hanger Alum Steel 12-0310-1
Structural Back Upper Structural Back Lower
Side Panel Painted Side Panel Stainless Steel
Japan/Australia 12202-1
Vessel Assembly Mild Steel (M/S) US/CE/Export (March 1998
Vessel Assembly Stainless Steel (S/S)
US (before March 1998) 12082NV
and later) (except Japan & Australia)
Japan/Australia 12202-2 US (before March 1998) Not Used US/CE/Export (March 1998
and later) (except Japan & Australia)
12-0401 12-0402
12-0380 12-0381
12188-1
12188-2
9 Frying Basket 2607 10 Clean-out Rod 14-0193 11 Drain Valve 2066-1
12 13 Drain Extension Nipple 44-1363
14
15 Burner Heat Shield 12-0349
16
17 Gas Manifold 36-0027 18
19
Vessel Back Panel Assembly Alum Steel Vessel Back Panel Assembly S/S
Orifice, Natural Gas-USA,AUST(BLK) Orifice, Natural CE-G20(BLU),G25(BLU) Orifice, Propane Gas-USA,AUST(ORG) Orifice, Propane CE-G31(RED)
Burner, L/H Burner, Center Burner, R/H
Pilot Burner, Natural Gas Pilot Burner, Propane Gas
Thermopile, for MV System-USA,Aust Thermocouple, Aust MV
12204-1 12204-2
14-0067-38(2.58MM) 14-0067-49(1.90MM) 14-0067-52(1.61MM) 14-0067-59(1.28MM)
14-0912-1 14-0912-2 14-0912-3
2146 2147
2513 1149
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Item No. Description Dean P/N
20
21 21
22
23
24 Diffuser 36006 25 Front Panel Stainless 12-0309-2 26 Vessel Vat Cover 12-0355
27
28 Leg w/mounting plate, 4 hole 2698
Operating Thermostat Operating T-Stat, Knob Only
Hi-Limit Switch - USA, Aust 435oF set point Hi-Limit Switch – CE 410oF set point
Comb Gas Valve, Honeywell, Natural-USA Comb Gas Valve, Robertshaw, Natural-USA Comb Gas Valve, Robertshaw, Nat-Aust Comb Gas Valve, HW CE Nat – G20, G25
Comb Gas Valve, Robertshaw, Propane-USA Comb Gas Valve, Robertshaw, Prop-Aust Comb Gas Valve, HW CE Prop – G31
Adapter Robertshaw (ECO), Aust, (FOR 2719 & 2720) Connector (ECO), CE (FOR 8072122 & 8072121)
2557 1205
2507 2687
2587 1896 2719 8072122
2589 2720 8072121
2722 8121256SP
29A 29B
30 Rigid Caster 2700 31 Handle 1039 32 Door Handle 1039-2 33 Cabinet Door 12183-2 34 Frame Assembly SR38FRCOMP
35 Lower Hinge Bracket 12-0379 36 Shim Leg and Caster 4 hole 9002949
Igniter,Piezo (Australia) Electrode (Australia)
8101001 2560
ITEMS NOT SHOWN ON PARTS DRAWINGS:
Pilot Assembly, Comp, HW, Nat Gas USA 14200-1; Propane Gas 14200-2 Pilot Bracket, Aust/CE, Electrode/Thermopile Adapting, 12-0400 Conversion Kit, Honeywell, Nat to Prop, USA, 12192; Prop to Nat, 12191 Conversion Kit, Robertshaw, Nat to Prop, USA, 12109-2 Conversion Kit, Robertshaw, Nat to Prop, Australia, 12217 (Instructions 12218) Conversion Kit, Robertshaw, Prop to Nat, Australia, 12221
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7. COMPONENT LISTING AND INSTALLATION STANDARDS (U.S.A. AND CANADA ONLY)
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
INSTALLATION
COMPONENT
STANDARD
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
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
STANDARD
ANSI/NFPA 96-1987 ANSI/NFPA 96-1987
ANSI/NFPA 12-1989
ANSI/NFPA 17-1990
ANSI/MFPA 13-1989
Smoke Detectors
Heat Detectors for Fire Protective Signaling Devices
ANSI/UL 521-1988
CAN/ULC-S530-1978
ANSI/UL 521-1988
ULC-S530-1978
24
ANSI/NFPA 72B-1986
ANSI/NFPA 72B-1986
Page 27
Dean, 8700 Line Avenue, Shreveport, Louisiana 71135
TEL 1-318-865-1711 FAX (Parts) 1-318-219-7140 (Tech Support) 1-318-219-7135
PRINTED IN THE UNITED STATES
SERVICE HOTLINE
1-800-551-8633
Price: $6.00
819-5707 04-99
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