Star Manufacturing 404A Installation Manual

Star
Manufacturing
International Inc.

10 Sunnen Drive
St. Louis, MO 63143

Phone: [phone]
Fax: [phone]

2M-Z1444 Rev. D 2/17/04

Installation

and

Operating

Instructions

STAR-MAX COUNTER GAS FRYERS

MODELS

404A, 615FA, and 630FA

615FA

630FA

1

SAFETY SYMBOL

This symbol is intended to alert the user to the presence of important
operating and maintenance instructions in the manual accompanying
the appliance.

RETAIN THIS MANUAL FOR FUTURE REFERENCE

NOTICE

Using any part other than genuine Star factory supplied parts relieves
the manufacturer of all liability.

NOTICE

Star reserves the right to change specifications and product design
without notice. Such revisions do not entitle the buyer to corre­sponding changes, improvements, additions or replacements for
previously purchased equipment.

MAINTENANCE AND REPAIRS

Contact your local authorized service agent for service or required maintenance. Refer to the authorized service
center listing provided with the unit. The Star Service Help Desk (1-800-807-9054) is available during normal
business hours to answer any questions that may arise. Please have your model number and serial number for
faster service.

2

GENERAL INSTALLATION DATA

CAUTION

This equipment is designed and sold for commercial
use only by personnel trained and experienced in its
operation and is not sold for consumer use in and
around the home nor for use directly by the general
public in food service locations. For equipment to be
used by the general public, please contact the factory.

The installation of the Appliance should conform
to the NATIONAL FUEL GAS CODE "ANSI
Z223.1 - LATEST EDITION" AND ALL LOCAL
GAS COMPANY RULES AND REGULATIONS.

FRYER SHOULD BE RESTRAINED TO PREVENT
TIPPING WHEN INSTALLED TO AVOID
SPLASHING OF HOT LIQUID. USE ADEQUATE
TIES WHEN INSTALLING THE FRYER.

FOR YOUR SAFETY

DO NOT STORE OR USE GASOLINE OR
OTHER FLAMMABLE VAPORS AND LIQUIDS
IN THE VICINITY OF THIS OR ANY OTHER
APPLIANCE. KEEP THE APPLIANCE AREA
CLEAR AND FREE FROM COMBUSTIBLES.

AIR SUPPLY

Provisions for adequate air supply must be provided.

IN CANADA INSTALLATION SHALL BE IN
ACCORDANCE WITH THE CURRENT CAN/
CGA-B149.1 NATURAL GAS INSTALLATION
CODE OR CAN/CGA-B149.2 PROPANE
INSTALLATION CODE AND LOCAL CODES
WHERE APPLICABLE.

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 the equipment.

This appliance and control valve must be disconnected
from the gas supply piping system during any pressure
testing of that system at test pressures in excess of
1/2 PSIG (1.034 ATM). This appliance must be isolated
from the gas supply piping system by closing its individual
manual shutoff valve during any pressure testing of the
gas supply piping system at test pressures equal to or
less than 1/2 PSIG (1.034 ATM). For your protection,
we recommend a qualified installing agency install this
appliance. They should be familiar with gas installations
and your local gas requirements. In any case, your gas
company should be called to approve the final
installation. In addition, there should be posted, in a
prominent location, detailed instructions to be followed
in the event the operator smells gas. Obtain the
instructions from the local gas supplier.

AIR INTAKES IN BOTTOM

Make certain that the air intake opening in the bottom
of the appliance is not obstructed. It is essential for
proper combustion and operation of the appliance.

CAUTION

DO NOT USE SPACE UNDER FRYER FOR
STORAGE

LEVELING UNIT

Level unit by adjusting the (4) feet.

CAUTION

DO NOT INSTALL WITHOUT FEET.

CLEARANCE

Clearances from combustible and non-combustible
material must be a minimum of 48" from the top of the
appliance and 6" from the sides and back. Adequate
clearance should also be provided for proper operation
and servicing.

EXHAUST CANOPY

It is essential that facilities be provided over the fryer
to carry off fumes and gases. This unit is not to be
connected to a flue or stack for exhaust purposes.

3

GAS PIPING

Gas piping shall be new, clean and of such size and so
installed as to provide a supply of gas sufficient to meet
the full gas input of the appliance. If the appliance is to
be connected to existing piping, it shall be checked to
determine if it has adequate capacity. Joint compound
(pipe dope) shall be used sparingly and only on the
male threads of the pipe joints. Such compounds shall
be resistant to the action of L.P. gases.

GAS PRESSURE REGULATOR

The regulator is factory set as specified on the rating
plate. If it should be necessary to check the manifold
pressure, remove the 1/8" pipe plug from the top part
of the burner manifold and attach a pressure gauge. To
adjust gas pressure, unscrew cap from pressure
regulator on control valve and turn screw to the right
to increase and left to decrease the gas pressure to its
proper setting. Replace cap.

WARNING: Any loose dirt or metal particles
which are allowed to enter the gas lines on the
appliance will damage the automatic valve and
affect its operation. When installing this appliance,
all pipe and fittings must be free from all internal
loose dirt. Do not remove the seal until actual
connection is made to the gas supply line.

CONNECTING GAS SUPPLY LINE

The gas inlet on this appliance is sealed at the factory
to prevent entry of dirt. Do not remove this seal until
actual connection is made to the gas supply line. Each
unit is supplied with a gas pressure regulator adjusted
for use with the gas specified on the nameplate. To
connect gas supply, attach pipe nipple provided with
unit. For pressure requirements and adjustment of
regulator, see GAS PRESSURE REGULATOR.

MANUAL SHUT OFF VALVE

A manual shut off valve should be installed upstream
from the union and within six feet of the appliance.

CHECKING FOR GAS LEAKS

Soap and water solution, or other material acceptable
for the purpose of locating gas leaks shall be used.
MATCHES, CANDLES, FLAME OR OTHER
SOURCES OF IGNITION SHALL NOT BE USED
FOR THIS PURPOSE.

LIGHTING INSTRUCTIONS

1. Wait 5 minutes before relighting pilot.

2. Open front door.

3. Turn thermostat to "OFF" position.

4. Turn valve knob to "PILOT." Push knob in
completely. Light pilot through opening on front of
unit. Hold button in for sixty seconds or until pilot
remains lit.

5. Check if drain valve is in closed position.

6. Add liquid fat as required.

7. Turn valve knob to "ON." Set thermostat to
desired temperature.

8. To turn all gas off to valve control and to pilot, turn
valve knob to "OFF" position (complete shutdown).

TO ADJUST PILOT

1. Open the front door panel.

2. Remove slotted screw cap adjacent to pilot gas
outlet of the control gas valve.

3. Turn inner screw to the right or left to decrease or
increase pilot flame. (Flame must surround
thermocouple tips by approximately 1/2" (1.2cm).)

4. Replace slotted screw cap tightly to prevent gas
leakage.

4

THERMOSTAT RECALIBRATION

1. To determine whether or not the thermostat
should be recalibrated, use an accurate
thermometer located approximately in the center
of the kettle with the bulb 1" (2.4cm) below the
top of the fat.

2. Set thermostat to 350°F (177° C) and check the
thermometer reading when burner flame goes
off. Temperature should be approximately 5°F
(3°C) less than thethermostat dial setting.

3. If not:
a. Without disturbing thermostat, pull knob

forward and remove from shaft.

b. Turn screw in center of shaft clockwise to

decrease temperature or counterclockwise
to increase temperature. NOTE: 1/4 turn of
this screw will result in a change of
approximately 30°F (17°C).

c. Replace knob.

4. Repeat steps 1, 2 and 3 until correct.

HIGH LIMIT THERMOSTAT

These units are equipped with a manual reset high
temperature limit type thermostat. This thermostat
will shut off the electric current to the magnetic gas
valve, which shuts off the gas if the fat temperature
reaches 450° F (232° C). The fryer will not operate
until the red reset button is pushed in.

OPERATING INSTRUCTIONS

1. CLEAN KETTLE thoroughly before using. Remove
baskets and crumb tray. Clean protective oil from
interior of kettle with a solution of washing soda or
equal. Drain through valve in bottom and rinse
thoroughly with clear water and dry completely
before filling with oil.

2. DRAIN VALVE - Make certain it is closed before
adding fat.

3. ADD FAT ­Model 615FA/630FA - A fat level line on the rear
of the kettle will guide you in determining the
minimum fat level (12" fryers have a 15 lb. (6.8kg)
fat capacity, 24" fryers have a 30 lb. (13.6kg) fat
capacity). If solid fat is used, pack the solid fat
carefully to the sides and bottom of the kettle
before turning the temperature control knob to
the "ON" position.
Model 404A - Keep level of fat 2" (5cm) above
tubes. Kettle holds approximately 18 lb. (8.2kg) of
fat. If solid fat is used, melt the solid fat before filling
the fryer. Never attempt to use solid shortening
to fill kettle.

A higher fat level can be used when frying bulky
foods, such as chicken or fish cakes. The level
should be chosen carefully so that the foaming
action does not spill out of the kettle.

Should the high temperature limit thermostat operate,
the temperature regulating thermostat should be
checked for malfunctions. The high limit thermostat
is located inside the fryer to your right and can be
reached when the door is open.

CAUTION

DO NOT REMOVE FEET!
DO NOT HEAT AN EMPTY KETTLE.

CAUTION

HOT FAT IS POTENTIALLY DANGEROUS. DO
NOT COME IN DIRECT CONTACT WITH HOT
FAT.

4. Turn the valve knob to "ON" position.

5. TEMPERATURE CONTROL - The thermostat is
a combination switch and heat control. The "OFF"
position will turn off the electric current which
closes the gas valve. With the fat in the kettle
(Note: On models615FA/630FA, solid fat must
be carefully packed to the sides and bottom of the
kettle) turn the thermostat knob to 200° F (93°C).

6. CRUMB TRAY Model 615FA/630FA - Place the
crumb tray in the kettle when the fat has melted.
BASKET RACK Model 404A - Place the rack
before adding fat.

5