Keating Instant Recovery, 10x11 14 CMG Service Manual

INSTANT RECOVERY® GAS FRYER SERVICE MANUAL
KEEP THIS MANUAL FOR TRAINING NEW PERSONNEL
1-800-KEATING
Gas Fryer pre2000 0107 09/07
TABLE OF CONTENTS
SECTION I INTRODUCTION
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . .1-2
SECTION II INSTALLATION
Damage During Shipment . . . . . . . . . . . . . . . . . . . .2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Restraining Devices . . . . . . . . . . . . . . . . . . . . . . . . .3
Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . .4
Gas Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SECTION III OPERATING THE FRYER
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Melting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Cooking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
Cleaning and Boil-Out . . . . . . . . . . . . . . . . . . . . .8-9
Electronic Timers . . . . . . . . . . . . . . . . . . . . . . . . . . .9
SECTION IV MAINTENANCE
Warranty Repairs . . . . . . . . . . . . . . . . . . . . . . . . . .10
Preventive Maintenance . . . . . . . . . . . . . . . . . . . .10
Oil Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Limited Calibration . . . . . . . . . . . . . . . . . . . . . . . . .10
Thermostat Bulb Positioning . . . . . . . . . . . . . . . . .11
Hi-Limit Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
SECTION V SERVICE DIAGNOSIS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Trouble Shooting Charts . . . . . . . . . . . . . . . . .12-13
SECTION VI PARTS LIST
Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Warning and Operating Plates . . . . . . . . . . . . . . .14
Gas Fryer Parts List . . . . . . . . . . . . . . . . . . . . . . .14
Gas Fryer Assembly . . . . . . . . . . . . . . . . . . . . . . .15
Runner Pilot Assembly . . . . . . . . . . . . . . . . . . . . .16
AA and CMG Control Panel Parts List . . . . . . . . .17
BB & TS Control Panel Parts List . . . . . . . . . . . . .18
14” - 34”x24” Basket-Lift
Control Panel Parts List . . . . . . . . . . . . . . . .19
14” Basket-Lift Housing Parts List . . . . . . . . . . . . .20
18”-24" Basket-Lift Housing Parts List . . . . . . . . . .21
SECTION VII WIRING DIAGRAMS
AA and CMG Wiring Diagram . . . . . . . . . . . . . . . .22
BB Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . .23
TS Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . .23
Basket-Lift Wiring Diagrams . . . . . . . . . . . . . . . . .24
Warranty
i
POST THIS LABEL IN A
PROMINENT LOCATION ON
YOUR UNIT
WARNING
IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.
FOR YOUR SAFETY
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
IMPORTANT
IN THE EVENT A GAS ODOR IS DETECTED, SHUT DOWN UNITS AT MAIN SHUT OFF VALVE AND CONTACT THE LOCAL GAS COMPANY OR GAS SUPPLIER FOR SERVICE.
I INTRODUCTION
SAFETY PRECAUTIONS
WARNING
THIS SYMBOL WARNS YOU THAT SERIOUS BURNS OR OTHER INJURIES MAY RESULT IF SAFETY INSTRUCTIONS ARE NOT FOLLOWED.
This service manual should be retained in a safe
place for future reference. The installation of your new fryer must conform to local codes or in the absence of local codes, with the current National Fuel Gas Code ANSI Z223.1/NFPA 54, Natural Gas Installation Code CAN/CGA-B149.1 or Propane Installation Code CAN/CGA-B149.2.
Your ventilation hood, when installed, must conform
to the current ANSI/NFPA 96 standard.
No frame or restriction shall be constructed around
the fryer that will restrict air movement into the fryer’s combustion area or prevent proper ventilation.
Keating fryers are designed to operate on the gas
fuel specified on the serial plate (attached to the inside of the door of the fryer) and must not be operated with another gas fuel. They cannot be converted to another gas fuel by turning or engaging a switch.
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any appliance.
You will post, in a prominent location, instructions to be followed in the event the user smells gas. This information shall be obtained from your local gas supplier. You may use the yellow stick-on label temporarily until you receive the data from your local gas supplier.
IMPORTANT: In the event a gas odor is detected, shut down unit at main shut-off valve and contact the local gas company or gas supplier for emergency service.
You must maintain this appliance free and clear from combustibles.
You must maintain the following minimum
clearances from combustible and noncombustible construction:
You must install this appliance at least 16 inches
away from any open flame.
Adequate clearance for servicing and proper
operation must be maintained. Your fryer is designed to be serviced from the front.
Keating commercial fryers are intended for other
than household use.
ALWAYS instruct new employees on proper fryer
operation.
A fryer should be operated ONLY by properly trained
personnel.
ALWAYS turn fryer off each night.
ALWAYS disconnect fuel source before servicing.
NEVER leave a fryer unattended during operation.
NEVER move a fryer when full of hot oil.
NEVER introduce objects or liquids into fryer, while
operational, which are not designed or made for cooking.
THIS FRYER MAY NOT BE ALTERED, MODIFIED
OR CHANGED IN ANY WAY.
The State of California enacted the California Safe drinking water and Toxic Enforcement Act of 1986, (Prop. 65), which “prohibits any person in the course of doing business from knowingly and intentionally exposing any individual to a chemical known to the State of California to cause cancer or reproductive toxicity without first giving clear and reasonable warning to such individuals.” The Governor’s Scientific Advisory Panel added carbon monoxide
to the list of hazardous chemicals known to cause reproductive harm.
In order to establish full compliance with Proposition 65, we attached a yellow warning label to each gas fired fryer manufactured by Keating of Chicago, Inc.
Carbon monoxide would not be present in concentrations that would pose a “significant risk” to the consumer when the equipment is installed, operated and maintained as follows:
1
Clearances
Combustible Noncombustible
Construction Construction
Back 6” 0”
Right Side 6” 0”
Left Side 6” 0”
2
Installed in accordance with all local codes, or in
the absence of local codes, with the current National Fuel Gas Code Z223.1/NFPA 54, Natural Gas Installation CAN/CGA-B149.1 or Propane Installation Code CAN/CGA-B149.2
Installed under a properly designed operating
exhaust hood.
Connected to the type of gas for which the fryer is
manufactured.
Pressure regulator installed in the appliance is
adjusted for the manifold pressure marked on the serial plate.
Adequate air supply to the fryer.
In-line pressure regulator, not supplied by Keating,
must be installed outside the appliance (when needed to maintain the specificied manifold pressure marked on the serial plate).
The equipment is operated in the manner intended
using the proper utensils.
Keep the equipment clean and have it checked
periodically.
Burner air adjustments, mechanical maintenance
and repairs must be performed by qualified service personnel.
If the equipment is not installed, operated and maintained in accordance with the above, concentrations of carbon monoxide in excess of the established limits could be present in the kitchen environment.
ALL PERSONNEL IN THE WORK PLACE WHO MAY BE SUBJECT TO ANY EXPOSURE OF CARBON MONOXIDE MUST BE WARNED OF SUCH POSSIBLE EXPOSURE. THIS WARNING SHOULD BE CONVEYED IN A MANNER SO THAT IT IS CLEARLY UNDERSTOOD BY THE EMPLOYEE, AND THE EMPLOYEE SHOULD BE ASKED IF IN FACT HE OR SHE UNDERSTANDS THE CORRECT METHOD OF OPERATION OF THE EQUIPMENT AND THAT A RISK OF EXPOSURE EXISTS IF THE EQUIPMENT IS OPERATED IMPROPERLY.
WARNING IF NOT INSTALLED, OPERATED AND MAINTAINED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS, THIS PRODUCT COULD EXPOSE YOU TO SUBSTANCES IN FUEL OR IN FUEL COMBUSTION WHICH CAN CAUSE DEATH OR SERIOUS ILLNESS AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
II INSTALLATION
This fryer MUST be installed, inspected, calibrated and serviced by qualified and/or certified and/or licensed service personnel – you may void your Keating warranty if installation is not completed per current local, national and Keating specifications. Contact your dealer for assistance.
DAMAGE DURING SHIPMENT
The fryer has been assembled, tested and inspected at the factory. Upon arrival, the complete fryer should be checked for any damage that may have occurred during shipment.
The carrier is responsible for all damage in transit whether visible or concealed. Do not pay for the freight bill until the fryer has been thoroughly checked for damage. If concealed damage is found later, contact the carrier immediately to file a claim.
What to do if equipment arrives damaged:
VISIBLE LOSS OR DAMAGE—Be certain to note this on the freight or express receipt and have it signed by the delivery person.
FILE CLAIM FOR DAMAGES IMMEDIATELY – Regardless of extent of damage.
CONCEALED LOSS OR DAMAGE—If damage is noticed when equipment is unpacked, notify the freight company immediately, and file a “concealed damage claim”. This MUST be done immediately. Be sure to retain the shipping container for inspection.
Keating does not assume responsibility for Loss OR Damage incurred in transit.
INSTALLATION
Installation must conform with local codes or, in absence of local codes, with the current National Fuel Gas Code Z223.1/NFPA 54, Natural Gas Installation CAN/CGA–B149.1 or Propane Installation Code CAN/CGA-B149.2.
POSITIONING
The fryer must be no closer than 6 inches from any combustible material and 16 inches away from any open flame. The fryer must be placed under an exhaust hood with a fire retardant system. Your ventilation hood, when installed, must conform to the current ANSI/NFPA 96 standard. ALL connections and placement must comply with local and national codes. It is the responsibility of the owner and local installer to comply with these regulations when installing the fryer.
Counter model and floor model fryers must be restrained to prevent tipping when installed in order to avoid splashing, spilling, etc. of hot liquid. The restraining method may be a manner of installation or by separate means.
LEVELING
The fryer will operate at its highest efficiency when properly leveled. Place a level on fryer vessel from side to side. For fryers on legs, the bottom foot of the leg is adjustable. Turn counter clockwise to decrease height or clockwise to increase height until level. For fryers on casters, the casters are adjustable by loosening the jam nut and turning the caster in or out. When the desired level is reached, tighten the jam nut. Adjustments of more than 3/4” are not recommended on any caster. The same procedure should be followed to level the fryer from front to back.
Figure 2-1
RESTRAINING DEVICES
On fryer installations with casters, casters and jam nuts must be completely tightened. Adequate means must also be provided to limit the movement of the appliance without depending on the connector, the quick-disconnect device or its associated piping to limit the appliance movement.
Connectors must comply with the current ANSI Z21.69/CAN 1 CAN/CGA 6.16 standard for connectors for movable gas appliances. Quick-disconnect devices must comply with the current ANSI Z21.41/CAN 1 6.9 standard for quick-disconnect devices for use with gas fuel as applicable.
WARNING IF DISCONNECTION OF THE RESTRAINT IS NECESSARY, IT MUST BE RECONNECTED WHEN THE FRYER IS RETURNED TO ITS ORIGINALLY INSTALLED POSITION.
GAS CONNECTION
WARNING
PIPE JOINT COMPOUNDS RESISTANT TO PROPANE GASES MUST BE USED.
BEFORE OPERATING THIS FRYER, CHECK PIPE JOINTS FOR LEAKS BY USING A SOAP AND WATER SOLUTION ONLY. DO NOT USE AN OPEN FLAME!
ON AN AA OR CMG (MILLIVOLT) FRYER, DO NOT SHORT GAS VALVE TERMINALS WHEN TESTING WIRING AS THERMOSTAT AND GAS VALVE DAMAGE MAY OCCUR AND CAUSE UNSAFE CONDITIONS.
Figure 2-3
Main Gas Connection (14TS Model)
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
You will post, in a prominent location, instructions to be followed in the event the user smells gas. This information shall be obtained from your local gas supplier. You may use the yellow stick-on label enclosed on page “i” temporarily until you receive the data from your local gas supplier.
Connect the fryer to the main gas supply line at the rear of the fryer. The piping should be a minimum of 3/4” IPS supply pipe for a single fryer. Batteries require larger supply lines. Installation must conform with local codes, or in the absence of local codes, with the current National Fuel Gas Code ANSI Z223.1/NFPA 54, Natural Gas Installation Code CAN/CGA-B149.1 or Propane Installation Code CAN/CGA-B149.2.
3
4
A 3/4” NPT manual gas valve is factory installed with each floor model fryer (for single fryers and batteries), except for 10x11AA – 20AA models which use a 1/2” NPT valve. The required gas pressure for proper operation of each fryer is 4” water column for natural gas and 10” water column for Propane gas at the burner manifold. Remove the allen head test plug on the gas manifold and use a manometer to check the gas pressure.
In-line pressure regulators are not supplied by Keating. They are to be provided and installed by others as directed by local codes.
NOTE: If more than one gas fryer is on the same supply line, you may require a larger line. Consult your local gas company to assure adequate volume and pressure. Refer to serial plate for proper gas requirements for your particular model.
ELECTRICAL CONNECTION
The Keating Instant Recovery® Gas fryer is equipped with a 9’ neoprene covered, 3 wire electrical cord with a three-pronged grounded plug for protection against electrical shock. This plug must be placed into a 120V properly grounded three-pronged outlet (NEMA 5-15 or 5-20). For proper grounding procedures see local codes or, in the absence of local codes, the current National Electrical Code ANSI/NFPA 70 or Canadian Electrical Code CAN 22.2 as applicable.
NOTE: AA and CMG Models do not require any outside electrical connections.
NOTE: The electrical wiring diagram for the fryer is attached to the inside of the fryer door and to the inside of this manual.
WARNING DO NOT CUT OR REMOVE THE GROUNDING PRONG FROM THIS PLUG.
GAS LEAK TESTING
Prior to lighting your fryer:
1. Make sure all thermostats, switches and safety
valves are in the “OFF” position.
2. Turn main On/Off manual gas valve to the “ON”
position.
3. Have your plumber or gas company check for
leaks with a soap solution or sniffer. (NEVER check with an open flame!)
4. Have your plumber or gas company representative light the constant pilot. (Not necessary if your fryer has an optional spark ignitor.)
NOTE: It is estimated that half of all service calls made on Keating Instant Recovery® Gas fryers result from an inadequate gas supply. During installation, have a gas company representative make certain that the fryer is receiving adequate gas pressure and volume.
WARNING PROPANE GAS MAY EVENTUALLY LOSE ITS ODOR AND PRECAUTIONS SHOULD BE TAKEN TO ASSURE THAT IT IS NOT PRESENT EVEN THOUGH YOU DO NOT DETECT AN ODOR. IF THERE IS ANY DOUBT, YOU SHOULD CALL YOUR LOCAL PROPANE GAS SUPPLIER FOR ASSISTANCE.
III OPERATING
FILLING
NOTE: Before filling the fryer make certain the fryer
vessel is sanitized, dry and the drain valve is completely closed. See figure 3-4 on page 7 for location of drain valve.
CAUTION: We recommend that solid shortening not be used in AA and CMG Model fryers as they are not equipped with a melt cycle. If solid shortening is used, it should be melted prior to filling the fryer vessel. Damage done by melting solid shortening in the fryer vessel will void the warranty.
WARNING BE SURE THE HEAT TRANSFER TUBES ARE COMPLETELY COVERED WITH OIL BEFORE SWITCHING THE FRYER ON. IF OIL LEVEL DROPS BELOW TOP OF HEAT TRANSFER TUBES, SEVERE DAMAGE TO FRYER AND INJURY TO OPERATOR MAY RESULT!
WARNING
WATER (IN ANY FORM) AND HOT OIL DON’T MIX!!!
CAUTION: Oil expands when heated. The “Fill Level”
line has been provided to ensure optimum cooking while ensuring the safety of the operator. Do not overfill the fryer vessel.
Figure 3-1
Fill Level Line
A. AA and CMG Models
1. Fill the fryer vessel with oil or MELTED solid shortening up to the “Fill Level” line.
B. BB, TS, CPU and Basket-Lift Models
1. Fill the fryer vessel with oil up to “Fill Level” line. (See Figure 3-1).
2. If solid shortening is used, remove screen and firmly pack solid shortening between the heat transfer tubes. After this has been done and the fryer has been lit, proceed to melting instructions (Page 6) for use of the melt cycle.
LIGHTING
WARNING BEFORE ATTEMPTING TO LIGHT THE FRYER, MAKE SURE THE GAS CONNECTIONS ARE SECURE AND HAVE BEEN LEAK TESTED AND THE FRYER HAS BEEN PROPERLY FILLED WITH OIL.
NOTE: For safety purposes, all Hi-Limit controls are
manually reset. Always check the Hi-Limit reset button before attempting to use the fryer. If the Hi-Limit has tripped, the fryer will not operate. (Located behind the fryer door underneath the front panel).
NOTE: For a fryer with a Central or Zero-Space™ Filter, always check the rear drain operating handle before attempting to use the fryer. A safety switch prevents the fryer from operating if the handle is not pushed in completely and latched. (See figure 3-2)
Figure 3-2
Rear Drain Operating Handle
A. AA and CMG Models
1. Open the main gas supply to unit (usually at rear) by turning handle in-line with gas piping or hose. Also open manual valve (red gas cock) on gas piping inside unit where applicable.
2. Light the constant pilot (located near far left burner) with a match.
3. Set the On/Off switch to the “ON” position.
4. Rotate the tan gas valve knob to the “PILOT” position.
5. Push in knob and the constant pilot will ignite the runner pilot tube. Hold the knob for 45 seconds and release slowly. If the runner pilot tube fails to stay lit, wait five minutes before attempting to re-light to allow any accumulated gas to escape.
6. After runner pilot tube stays lit, release knob and rotate it to the “ON” position.
7. Set thermostat to desired temperature (325°F ­335°F).
B. BB, TS, CPU and Basket-Lift Models
1. Open main gas supply to unit. Open manual valve (red gas cock) on piping inside unit where applicable.
2. Light the constant pilot (located near far left burner) with a match. If your fryer has an optional spark ignitor, omit this step.
3. Turn on main power On/Off switch to the “ON” position.
4. Set the Fry/Off/Melt switch (BB model) or Cook/Idle/Melt switch (TS and Basket-Lift models) to the “OFF” (BB) or “IDLE” (TS and Basket-Lift) position.
5. Activate pilot light momentary switch (for runner pilot) and hold about 30 seconds, releasing it after pilot indicating light is illuminated. If the runner pilot tube fails to stay lit, wait 5 minutes before attempting to re-light to allow any accumulated gas to escape.
6. Set the Fry/Off/Melt switch (BB model) or Cook/Idle/Melt switch (TS and Basket-Lift models) to the “FRY” (BB) or “COOK” (TS and Basket-Lift) position.
5
6
7. Set the thermostat to the desired temperature (325°F - 335°F).
MELTING
The Keating Melt Cycle safely melts solid shortening in the fryer vessel without scorching.
WARNING BEFORE ATTEMPTING TO USE THE FRYER, MAKE SURE THE FRYER HAS BEEN PROPERLY FILLED WITH OIL.
A. BB, TS and Basket-Lift Models
1. Set the thermostat to the desired frying
temperature (325°F - 335°F).
2. If using solid shortening, set the Fry/Off/Melt switch
(BB Model) or Cook/Idle/Melt switch (TS and Basket-Lift Models) to the “MELT” position. Stay in the “MELT” cycle until the shortening has melted completely and is at the “Fill Level” line before switching to the “FRY” (BB Model) or “COOK” (TS and Basket-Lift Models) position for cooking.
B. CPU Model
See separate fryer instructions or call 1-800-KEATING.
NOTE: During the “MELT” cycle, the burners are on for approximately 5 seconds and off for approximately 55 seconds.
WARNING BE SURE THE HEAT TRANSFER TUBES ARE COMPLETELY COVERED WITH MELTED SHORTENING BEFORE ATTEMPTING TO FRY. IF THE TUBES ARE NOT COMPLETELY COVERED WITH MELTED SHORTENING, SEVERE DAMAGE TO FRYER AND INJURY TO OPERATOR MAY RESULT.
COOKING
Keating Instant Recovery® Gas Fryers are designed to provide maximum production efficiency and deliver high quality food products. Low-temperature cooking, highly polished stainless steel and a true COLD ZONE mean extended oil life. Follow cooking procedures for your model.
WARNING
OPERATION OF THIS FRYER SHOULD BE
LIMITED TO PERSONNEL WHO HAVE BEEN THOROUGHLY TRAINED IN OPERATING PROCEDURES.
USE ONLY KEATING APPROVED BASKETS IN YOUR FRYER. NEVER OVERFILL FRY BASKETS. DO NOT BANG BASKETS ON BASKET HANGERS OR FRYER VESSEL.
CARE SHOULD BE TAKEN WHEN LOWERING BASKETS INTO FRYER TO PREVENT SPLASHING HOT OIL FROM FRYER VESSEL.
NEVER LIFT BASKETS DIRECTLY OUT OF THE FRYER VESSEL WITHOUT DRAINING AS SEVERE INJURY MAY RESULT.
A. AA, CMG and BB Models
1. Fill fryer as described on page 4 – Filling.
2. Set thermostat to the desired frying temperature (between 325°F - 335°F).
3. When the oil reaches the desired frying temperature, lower filled basket(s) slowly into the hot oil.
4. When cooking cycle is complete, carefully lift basket(s) out of oil and place them on basket hanger rods (on splashback of fryer) to allow draining of excess oil.
B. TS Model
1. Fill fryer as described on page 4 - Filling.
2. Set thermostat to the desired frying temperature (between 325°F - 335°F).
3. When oil reaches the desired frying temperature, the “HEAT” light will go off and the ”COOK” light will illuminate.
4. Lower filled basket(s) slowly into the hot oil.
5. Set timer for left or right side basket, whichever is being lowered into oil.
6. When timer sounds, carefully lift basket(s) out of oil and place them on basket hanger rods (on splashback of fryer) to allow draining of excess oil.
C. Basket-Lift Model
1. Fill fryer as described on page 4 – Filling.
2. Set thermostat to the desired frying temperature (between 325°F - 335°F).
3. When oil reaches the desired frying temperature, the “HEAT” light will go off and the “COOK” light will illuminate.
4. Fill basket(s) to proper level and place on upper bar of lift rod(s).
5. Set timer(s) to desired cooking time using up or down arrow buttons. For programming timers, see page 9.
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