Pitco 18WKS-UFM Service Manual

Installation/Operation /Service/Parts Manual

for the KFC Multivat Gas Fryers

Models 7-2WKS, 7-3 WKS, 7-4WKS

7-3 WKS & 7-4 WKS With UFM Spacefighter Filter

IMPORTANT

Installation

Warning: Improper installation, adjustment,

service or maintenance can cause property

damage, injury or death.

Read this entire manual thoroughly prior to

installation, operation, maintenance or service of

this equipment.

For Your Safety: Do not store or use gasoline

or other flammable vapors or liquids in the

vicinity of this or any other appliance.

Warning: Gas leak procedures, obtained from

your gas supplier, should be posted in a

prominent location.

Installation

For your protection, review and complete these safety awareness items: Gas

Ensure that the authorized installer complies with local codes Use the proper fuel type and the correct size supply lines Use a pipe joint compound suitable to propane gas in order to prevent gas leaks.

Electrical

Ensure that the electrician complies with local codes Use the 3-prong plug on the fryer to provide proper grounding and effective protection from shocks Always disconnect unit from the electrical supply before cleaning or servicing.

Fire

Both the fryer tank and the shortening may exceed 375°F (190°C)—keep shortening away from

operators and their clothing

Avoid moving the unit until shortening has cooled Always wear insulated, oil-proof gloves whe n cleaning and/or filtering the unit Keep the fryer area clear, especially of combustibles like paper Install fryer away from combustibles like wallboard Ensure that your fire detection/alarm/extinction equipment and your first aid kit are ready for use.

Ventilation

Proper ventilation promotes correct burner operation Inadequate ventilation may release a scentless, invisible, toxic gas: carbon monoxide Keep the flue vent clear to prevent overheating and fire

Eliminate down drafts which may cause unit malfunction; should you have any questions, please contact

your local authorized service representative.

Stabilility

Always reconnect the restraining device after moving caster models, thus maintaining gas-line integrity Relevel the unit with the provided mechanisms after movement for proper operation.

Warranty

Follow the installation instructions provided in this manual carefully Ensure that operators learn and follow guidelines for safety, operation, filtering, and cleaning

Keep this manual handy for ready reference.

Table of Contents

Installation

Installation:

Safety 1-2 Table of Contents 3-5 System Overview 6 Table of Specifications/Requirements 6 Guide to Unpacking the New Fryer 7 Checking Your Order 7 Installation Procedure 7 Figure L -1: Installing Fryer Accessories 8 Gas Piping Capacity 9 Gas Leak Testing 9 Electrical/Grounding System 9 Fuel/Gas System 10 Fire Detection/Extinction System 10 Preliminary Cleaning of the Fryer 11 Filling the Fryer 11 Installation Adjustments 11 Figure L -2: Cover the Burner Tubes 11

Operation:

Fryer Operations 12 Computer Controller 12 Daily and Weekly Cleaning of the Fryer 12 Filtration 12 Recovery Test 12

Maintenance

Pitco Spacefighter Filter Module 13 The Fryer Filtration System 14 Operator Troubl eshooting - Fryer 15-16 Operator Troubleshooting - Filter 17-18

Installation

Service:

Burner Manifold Pressure Adjustment 19 Main Burner Flame Adjustment 19 Pilot Burner Adjustment 19 Removing the Main Burner 20 Changing the Main Burner Orifice 20 Replacing the Heat Tube Baffles 20 Removing the Pilot Burner 20 Replacing the Pilot Orifice 21 Replacing the Limit Control 21

Troubleshooting:

Service Troubleshooting - Fryer 22-27 Service Troubleshooting - Filter 27-29

Photographs:

Key to Figure P-1 30 Figure P-1: KFC 7" Triple Fryer w/Controller 31 Key to Figure P-2 32 Figure P-2: Important Internal Parts 33 Key to Figure P-3 34 Figure P-3: Entrance Box, KFC 7-1 WKS Fryer 35 Key to Figure P-4 36 Figure P-4: Entrance Box, KFC 7-2 WKS Fryer 37 Key to Figure P-5 38 Figure P-5: Ignition Control Box 39 Key to Figure P-6 40 Figure P-6: Filter, Front View 41 Key to Figure P-7 42 Figure P-7: Filter Assembly 43 Key to Figure P-8 44 Figure P-8: Filter Pick -Up Assembly 45 Key to Figure P-9 46 Figure P-9: Filter, Interior Front 47

Installation

Parts Listings:

Fryers 48-49 Filters 49

Schematics:

KFC 7-3 & 7-4 with Filter N/A KFC 7 Series Non-Filter N/A KFC Single Fryer with Computer and EI N/A UFM 240 VAC Option N/A UFM 115 VAC Option N/A UFM 208/230 VAC Option N/A

Installation

Model

2WKS

3 WKS

4WKS

3WKS/UFM

4WKS/UFM

System Overview

The fryers and filter systems covered in this manual have been specially tailored by Pitco Frialator, Inc. for use in KFC stores. With proper installation, operation, and maintenance, you will recieve many years of dependable operation.

This manual covers the models 7-2WKS, 7-3 WKS, and 7-4 WKS multivat gas fryers, as well as the 7-3WKS-UFM and 7-4WKS UFM models. The WKS units require a portable filter unit, and the WKS-UFM models incorporate the Spacefighter built-in filter system. UFM filter systems make filtration quick, easy and possible during peak periods, eliminating the traffic obstruction and safety hazards of conventional filtration procedures.

All of the fryers are equipped with 16-gauge stainless steel tanks. In addition, all of the fryers have electronic ignition systems, eliminating the need to light the pilot with a match. Another feature common to all of the fryers is the float switch, which cuts off power to the heating system should the shortening be inadvertantly drained, preventing scorching of the shortening and the tank itself.

These fryers are designed to work with the new generation of KFC proprietary FAST computer controllers. One computer can control up to two fryers simultaneously. These computers are purchased separately; instructions for installing the computer controller to the fryer are included in this manual.

Table of Specifications and Requirements

Dimensions

Height. Overall 47" 47" 47" 47" 47" Height. Work 35" 35" 35" 35" 35" Unit Width 20.31" 30.47" 40.62" 30.47" 40.62" Depth/Front to Back 33.32" 33.32 33.32" 33.32" 33.32" Cooking Area/Tank 2-8 x 14 3-8 x 14 4-8 x14 3-8 x 14 4-8 x 14 Frying Depth 4" 4" 4" 4" 4" Fat Vol./Lbs./Min. 25 25 25 25 25 Aisle Space/Min. 21" 21" 21" 25" 25"

Gas Supply Requirements

Hourly BTU Input 110.000 165.000 220.000 165.000 220.000 Pipe Size/NPT/Min. 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 No. of Connections 1 1 1 1 1 Nat. LP Pressure/WC 7.0/12.0 7.0/12.0 7.0/12.0 7.0/12.0 7.0/12.0

Electrical Requirements

Volts/Amps 120V. 1A 120V, 1A 120V, 1A 120V. 8A 120V. 8A Supply Cords 1-15A 1-15A 1-15A 1-15A 1-15A Phase/Frequency 1.50/60 1. 50/60 1, 50/60 1. 50/60 1,50/60

Filter System

Filter Envelope - - - 14x15 14x15 Pump Rate/Clean - - - 5.0 GPM 5.6 GPM

Installation

Guide to Unpacking the New Fryer

Your 7-WKS series fryer will arrive in a single crate; if you ordered a Spacefighter UFM filter system, the filter unit will be strapped to the top of the fryer crate. As you unpack:

Find the packing slip (in a plastic envelope on the outside of the crate); locate the Sales Order Number on the packing slip When uncrating, keep the fryer's weight evenly distributed, and be careful not to strain the front or back casters and/or legs;

never pull on the flue vent

Inspect your fryer (and filter), inside and out: if any damage is detected, do not sign the bill of lading-report the damage to your

shipping representative immediately, as the shipper's liability has a 15-day limit

Note the unit's serial number on the plate inside the door Retain all packing materials until all parts of your order, standard and optional, have been tallied using the checklist below

Locate your Pitco Frialator guarantee; complete it by filling in the serial number of your fryer and the date Retain this document for future reference-store it in a safe place—DO NOT return it to Pitco Frialator.

Checking Your Order

Find the following with your Fryer Unit:

Fry Basket (1/fryer) Flue Heat

Fry Basket Hanger (1/fryer)

Fryer Crumb Scoop (1/fryer)

Deflector (1/fryer)

Find the following with your Filter Module:

Crumb Catch Basket

Channel Strip (1/pair of fryers).

14" x 15" Filter Bag Holder Ass'y Filter Pan.

If any parts and/or accessories are missing, call the plant using our toll-free number: 1-800-258-3708.

Installation Procedure

It is required that you have a qualified service technician perform the installation of the fryer; please supply the technician with this manual and have him/her follow the procedures given below.

 Bring the fryer to the area in which it will be connected to utilities and where it will be operating

 Connect gas piping to the fryer; refer to Specifications Table and the Fuel Gas System section of this manual for proper

pipe sizes

 lf you are going to install a flexible hose with a quick-disconnect, be sure that the disconnect has adequate flow capacity for the

particular model fryer

g NOTE: If you are installing a flexible hose, you must install a fryer restraining loop, shorter than the gas line itself—refer to the

Fuel Gas System section of this manual for further information

 Make sure you have the heat deflector(s) (1/fryer) provided by Pitco Frialator; clip onto the fryer prior to positioning the unit

under the ventilation system (refer to Figure L-1)

 Using a large, adjustable wrench or pliers, turn the large hex on the caster base to raise or lower each caster and level the

fryer.

Installation

Figure L -1: Installing Fryer Accessories.

Installation

Gas Piping Capacity

In order to achieve the degree of performance for which the fryer is designed, a well-planned and properly-sized gas supply

system is essential

Piping size should be appropriate to supply gas sufficient to the maximum demand of all appliances on the line without loss of

pressure at any of the equipment

Other criteria in determining gas piping size are the total BTU requirements of the equipment served and the length of piping

from the meter to the appliances

The installation must conform with local codes or, in the absence of local codes, with the National Fuel Gas Code, ANSI

Z223.1-1988

Your local gas company should consult the National Fuel Gas Code—Appendix C, Table C-4 (for natural gas) and Table C-16

(for propane)—for proper sizing and installation of gas piping

Also refer to the section of this manual covering Fuel/Gas Installation.

Gas Leak Testing

g NOTE: NEVER use an open flame to test for gas leaks

Before operating the fryer, test all fuel gas connections for leaks, using a solution of soap and water

If the gas-supply system is going to be tested at a pressure GREATER THAN 1/2 psig (3.45kPa), the fryer and its individual

shut-off valve must be disconnected from the supply line

If the gas-supply system is going to be tested at a pressure EQUAL TO OR LESS THAN 1/2 psig, the fryer's manual shut-off

valve must be closed during testing.

Electrical/Grounding System

North American electrical requirements: 120 VAC 60 Hz, 0.5 amp per fryer, 7 amps per filter system International electrical requirements: 220 (or 240) VAC 50 Hz, 0.5 amp per fryer, 4.0 amps per filter system The power cord with the straight-blade plug provides power for the filter module. The filter module plugs into a receptacle

located inside the fryer cabinet

The third prong on the fryer plug grounds the system for your protection against electrical shock—insert the plug directly into

a properly-grounded three-prong receptacle

gNOTE: NEVER remove the third, or grounding, prong from the plug

The fryer must be electrically grounded in accordance with local codes; if local codes do not apply, comply with National

Electrical Code, ANSI/NFPA 70-1990.

Installation

Fuel/Gas System

All gas service must comply with local codes; if local codes do not apply, install the fuel gas service in accordance with the

National Fuel Gas Code ANSI 7233.1-1988

In Canada install the fryer in accordance with CAN1-B149.1 and CAN1-B149.2 and/or local codes Contact the local gas company to determine the correct size for the gas supply line; the fryer will not operate properly if

the gas line is too small

When making the gas supply connections, use a pipe joint compound resistant to liquified petroleum gases Be certain that all gas-supply piping to the fryer allows for the proper minimum clearance at the side, rear and floor level—refer

to the data plate inside the front door

Level the fryer in accordance with the instructions provided in this manual Field-attached piping assemblies must not interfere with filter module travel or, if equippped with casters, the caster-swivel

radius

gNOTE: ALWAYS provide gas-supply connection lines that have been sized to be equivalent to the supply connection on the

fryer

g NOTE: NEVER use adaptors to make a smaller line fit, as an inadequate line size may not allow sufficient gas

volume for proper burner operation, resulting in poor fryer performance

Low gas volume/pressure can also cause "lazy" flames, which do not travel through the tank properly; this can cause high

temperatures on tank areas and create carbon monoxide

The fryer is equipped to work with one specific type of fuel gas—this information is given on the data plate inside the fryer door

gNOTE: NEVER supply the fryer with any kind of fuel other than the type indicated

Flexible hose quick-disconnect installation shall be made with a connector which complies with the "Standard for Connectors

for Moveable Gas Appliances", ANSI Z21.69-1987, and a quick-disconnect device which complies with the "Standard for Quick-Disconnect Devices for Use with Gas Fuel", ANSI Z21.41-1978 and Addenda Z21.41a-1981 and Z21.41b-1983

The restraining device must be shorter than the gas connector, to prevent strain on the gas connector A fryer restraining loop must be provided to limit the movement of the fryer without depending on the connector and the

quick-disconnect device, or its associated piping-to limit the fryer's movement

It is recommended that the attachment for the fryer restraining loop be installed in the rear center of the fryer cabinet (between

the two tanks) at approximately 30" above floor level

Use caution when drilling and installing attachment Do not locate in such a manner that the mounting screws will perforate either of the fryer flues.

Fire Detection/Extinction System

gNOTE: We STRONGLY ADVISE you to install an approved fire detection and extinguishing system.

Exhaust temperatures from the fryer may run as high as 1200°F; therefore, select a fire-extinguishing system and a

sensing device that activates your system with this in mind, in order to reduce the possibility of false alarm.

Installation

Preliminary Cleaning of the Fryer

£Please refer to the KFC Standards Library for this procedure.

Filling the Fryer

gNOTE: ALWAYS wear insulated, oil-proof gloves when working with the fryer.

To fill the tank with cooking medium:

£Close the drain valve £Check the computer probe/high-limit bulb clamp to ensure that screws are tight

gNOTE: NEVER melt solid shortening in the fryer, which will scorch the shortening. Melt it in pot on separate

stove prior to filling the fryer.

£Fill the tank with liquid and solid shortening to the OIL LEVEL line marked on the back

gNOTE: ALWAYS be sure that the burner tubes are covered before lighting the burners (see Figure L -1).

Installation Adjustments

£Have these adjustments performed by qualified personnel

£Get the following tools: Manometer or low -pressure gauge, digital thermometer or temperature probe £Check the computer probe/high-limit bulb clamp to ensure that screws are tight £Perform the pilot level adjustment (described in this manual) £Check the main burner manifold operating pressure £Check the main burner flame adjustment. £Procedures to follow in performing the checks listed above are provided in this manual.

Figure L -2: Cover the Burner Tubes.

Fryer Operation

£Remove any flammable material from fryer area £Check the gas supply: see that the fryer gas line is properly connected... £Turn on the building gas supply, if necessary £Turn on the ventilation hood £Check for the proper shortening level in each fryer £Tum on the manual gas knob in the fryer £Make sure that the computer controller is on, and press the on switch £The main burners will light and the computer will control the fryer £Should the burners fail to light, turn the power switch OFF £Wait 5 minutes before attempting to restart the fryer—this will allow any excess gas to dissipate.

Computer Controller

£For operating instructions, please refer to the KFC Standards Library regarding the computer controller.

Daily and Weekly Cleaning of the Fryer

Operation

£Refer to the KFC Standards Library for instructions regarding the correct cleaning procedures for the fryers.

Filtration

£Refer to the KFC Standards Library for the correct filtering procedures.

£Make sure that all filter system quick-disconnect fittings are completely connected and that at least one return or circulation

valve is open before starting pump

£When cleaning filter system parts, make sure to clean filter pickup screen (inside Item #8 on filter diagram).

Recovery Test

£Perform this test monthly to confirm that the fryer is heating efficiently-inefficient heating will result in improperly cooked

food product

£Use a watch with a second hand to time from the moment the display reads 275°F (135°C)... £...until the temperature reaches 300°F (149°C) £Note the amount of time necessary for the fryer to reach that temperature £Compare the time with the correct recovery range (1 minute) £If the time is higher than 1 minute and 30 seconds, contact maintenance.

Maintenance

operation will resume.

red button through access hole.

Pitco Spacefighter Filter Module

Features:

£Stores neatly under fryer when not in use £Allows for quick filtration, even under busy conditions £Heater system to liquify hardened shortening.

Warnings:

gAlways use insulated, oil-proof gloves when performing filter operations: pans of system can get hot enough to cause bums.

Part #: Part Name: Part Function:

1 Power Supply Cord Plugs into fryer receptacle to provide power for filter operation.

2 Circuit Breaker Generally left ON. Will trip if overload occurs, i.e. pump is turned on but no

system valves are open. To reset, find and correct cause of trip. Turn power switch (5) OFF. Push circuit breaker OFF, then return it to ON. Normal

3 Return Connector Quickly disconnects filter module from fryer oil piping. Allows easy access

to filter pick up for cleaning.

4 Pump Motor Thermal Overload Protects motor from high temperatures. Will trip only when pump is

extremely hot. To reset, allow to cool and find cause of overheat (see Troubleshooting), turn power switch (5) OFF, remove access cap (4), push

5 Pump/Heating Switch Turns pump on or activates internal heater to soften solidified shortening

before pumping. If filtration is to be done in the morning, start heaters at the same time you start the fryer—only necessary for solid shortening.

6 Heat Indicator Light Lights to indicate that the heaters are operating. 7 Filter Assy Quick-Disconnect Separates filter pick-up ass'y from piping for renewing filter envelope. Pull

back on collar, pull pick-up ass'y away from piping.

8 Pick-Up Tube Connects filter envelope ass'y to piping. Incorporates a strainer to protect

filter pump from grit in the event of envelope failure. Rinse pick-up tube thoroughly each time filter envelope is changed.

9 Crumb Catch Basket Catches biggest pieces of sediment to extend envelope usefulness. Clips over

front edge of pan. Special design reduces splashing oil.

10 Filter Pan Holds oil from the fry tank.

The Fryer Filtration System

Item #: Item Name: Function:

1 On/Off Switch Turns fryer on and off 2 Heating Indicator Lights when heat is on 3 Oil Return Valve Directs filtered oil to proper fry kettle 4 Filter Return Connector Allows filter unit to be removed for cleaning 5 Drain Valve Opens valve to drain shortening into filter 6 Gas Shutoff Valve Stops gas flow if unit is off for long period 7 Filter Power Supply Provides power to operate filter unit

8 Circulation Valve Rushes debris from drain system.

Maintenance

a. Temperature sensing probe RT1, (RT2), open

gas valve knob to OFF. Allow fryer

temperature. If necessary, consult a

a. Check that the fryer's gas knob is

Operator Troubleshooting - Fryer

The following procedures are preliminary troubleshooting procedures applicable to equipment operators. They outline some of the more common problems encountered in equipment operation, by checking these items before requesting

field service by a service technician, you may avoid unnecessary and costly service calls.

Problem Cause Solution

Computer display reads PROB.

or shorted.

a. Consult a qualified service technician. Fryer can run on auxiliary thermostat until repairs can be undertaken.

Computer display reads HI; alarm is heard. a. Temperature is greater than 40°F above set-

point.

Neither computer nor fryer power controls will come on.

Fryer heating light isn't lit: computer is on. a. No heat called for by computer. a. Normal operation.

a. Fryer power cord plug not plugged in. a. Plug fryer into appropriate

b. Ventilation hood not on. b. Turn ventilation hood on.

c. Fuse F1 open. c. Replace with proper fuse value:

b. Heat switch is OFF. b. Turn heat switch ON.

c. Fuse F3 is open. c. Replace fuse. NOTE: An open

a. Turn power to fryer OFF. Turn

to cool- Determine cause of over

qualified service technician.

receptacle.

if fuse blows again, call maintenance.

fuse often indicates some fault in the fryer's wiring. It may be necessary to locate the fault to restore operation.

Heat light is on. Computer is on. Fryer will not heat.

d. Consult a qualified service technician. d. Consult a qualified service

technician.

a. Gas is not turned on.

in the ON position; check the gas quick-disconnect (if used); check the building's gas supply.

b. Air has been trapped in fryer piping from disconnecting and reconnecting to gas line.

c. Food crumbs are stuck in float switch. c. Remove all food particles from

b. Unit will purge itself of air. Allow 15-30 minutes extra heat-up time.

float to assure free travel.

Maintenance

Heat light is on. Computer is on. Fryer will not heat (Cont).

Pilot and burners will not light, no sparking at pilot igniter. Fryer heating light is lit. Computer is on.

NOTE: If ignition system repeatedly locks out, call maintenance.

Pilot and main burners will not ignite. Spark is present at pilot igniter.

Main burners will not light. Pilot burner lights and goes out.

Burner flames will not enter heat tubes. a. Down-draft on fryer's flue opening. a. Protect flue opening from

d. Solid shortening is packed around float switch; float ball cannot float.

a. Air in gas line; ignition system locked out. a. Turn fryer off, then on. Fryer

b. Food crumbs are stuck in float switch. b. Remove all food particles from

a. Gas supply off. a. Check that all upstream valves

b. Fryer manual gas valve OFF. b. Turn gas valve knob ON: if

a. Gas supply system failure. a. Call maintenance.

d. Liquefy shortening in stock pot before filling fry tank.

will purge itself; allow unit to run for 15-30 minutes.

float to assure free travel.

in gas supply piping are open.

necessary, call maintenance.

downdrafts. breezes, or air flows from blowers.

Fryer temperature recovery is too slow. a. Excessive updraft on the fryer flue. a. Look for flames lifting off of

b. Ventilation hood not operating properly. b. Correct ventilation hood

malfunction. If necessary, call maintenance.

c. Fryers flue is obstructed or blocked. c. Remove obstruction or flue

blockage. If necessary, call maintenance.

burner face. Reduce exhaust blower speed or locate it at a greater distance from the fryer. If necessary, call maintenance.

b. Excessive downdraft on the fryer flue. b. Locate cause of draft—divert air

current.

c. Carbon buildup on heat tubes. c. Clean fry tank and change

shortening using procedure described in the KFC standard library: call maintenance.

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