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Frymaster FPD65 manual

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Table of contents for the manual

  • Page 1

    PARTS LIST PARTS LIST PARTS LIST PARTS LIST INCLUDED INCLUDED INCLUDED INCLUDED Frymaste r, a member of the Commercial Food Equipm ent Service Association , recommends using CFESA Certified Technicians . 24-Hour Serv ice Hot line 1-800- 551-863 3 M ARCH 2004 *8196039* *8196039* *8196039* *8196039* Frymaster FPD65 Series Gas Fryers Installation &[...]

  • Page 2

    Please read all sections of this manual and retain for future reference. NOTICE This appliance is intended for professional use only and is to be operated by qualified personnel only. A Frymaster/Dean Factory Authorized Service Center (FASC) or other qualified professional should perform installation, maintenance, and repairs. Installation, mainten[...]

  • Page 3

    DA NGE R Improper installation, adjustment, maintenance or se rvice, and unauthorized alterations or modifications can cause property damage, injury, or death. Read the ins tallation, operating and service instructions thoroughly before installing or servicing this equipmen t. Only qualified service personnel may convert this appliance to use a gas[...]

  • Page 4

    FPD65 Series Gas Fry ers Insta llation & Operat ion Man ua l TABLE OF CONTENTS Page # 1. INTRODUCTIO N 1-1 1.1 After Purchase 1-1 1.2 Ordering Parts 1-1 1.3 Service Informa tion 1-1 1.4 Computer Informat ion 1-1 1.5 Safety Information 1-2 1.6 Service Personnel 1-3 2. IMPORTANT INFORMATION 2-1 2.1 Receiving and Unpa cking Equipment 2-1 2.2 Gener[...]

  • Page 5

    FPD65 Series Gas Fry ers Insta llation & Operat ion Man ua l TABLE OF CONTENTS (CONT.) P age # 5. FILTRATI ON OPERATION 5-1 5.1 General 5-1 5.2 Filtration Preparat ion 5-1 5.3 Daily Filtration Operatio n 5-4 5.4 Operating th e Filter 5-6 6. PREVENTATIVE MAINTENANCE 6-1 6.1 General 6-1 7. TROUBLESHOO TING 7-1 7.1 General 7-1 7.2 Pilot Burner Mal[...]

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  • Page 7

    FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 1: I NTRODUCTI ON 1-1 1.1 After Purchase In order to impr ove s ervice , have the following chart filled in by the Frymaster/Dean Authorize d Service Technician who installed this equipment. Author ized Service Technician/FASC Addre ss Telephone/ Fax Model Num ber Serial Num b er Gas Type 1.2 Ordering Parts[...]

  • Page 8

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 1: INTRODUCTION 1-2 1.4 Computer Information (cont.) The user is cauti oned that an y changes or mo difications not ex pressly approved b y the part y responsible for compliance could void the user 's authority to operate the equipment. If necessary, the user should consult the dealer or an experienc[...]

  • Page 9

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 1: INTRODUCTION 1-3 1.6 Service Perso nnel 1.6.1 Definit ions A. Qualified and/or Author ized Operating Personnel 1. Qualified/authorized operating personnel are those who have carefull y read the information in this manual and have familiar ized themselves with the equipment functions, or have had previo[...]

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  • Page 11

    FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 2: IM PORT A NT INFORM A T I ON 2-1 2.1 Receiv ing and Unpacking Equipment A. Check that the containers are uprig ht. Use an ou tward prying motion - no ha mm ering - to remove the cart ons. Unpack f ryers carefull y and remove all acc essories from the carton and/or frypots. Do not discard or misplace ac c[...]

  • Page 12

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 2: IMPOR T ANT INFORMATION 2-2 2.2 General Qualified, licensed, and/or authorized installation or service personnel only (as defined i n Section 1.6) should perform the following: • Installation and service on Frymaster/Dean equipment. • Conversion of this appliance from one gas type to another. Failu[...]

  • Page 13

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 2: IMPOR T ANT INFORMATION 2-3 2.3 Princ i ples of Operation The incoming gas flows through orif ices and is mix ed wi th air in the burners to c reate the correct ratio for proper combustion. The mixture is ignited at the front end of each heat tube b y the pilot light. Internal diffusers sl ow the flame[...]

  • Page 14

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 2: IMPOR T ANT INFORMATION 2-4 2.5 Pre- Installation (cont.) B. Clearances : The fryer area must be kept free and clear of all combustible s. This unit is design - certifie d fo r the f ollowin g installa tions: 1. Commercial installation onl y (not for household use). 2. Non-combustible floor installatio[...]

  • Page 15

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 2: IMPOR T ANT INFORMATION 2-5 2.6 A ir Suppl y an d Ventilati on DA NGER This appliance must be installed with sufficient ventilation to prev ent the occurrence of unacceptable concentrations of substan ces harmful to the health of personnel in the room in which it is installed. Keep the area around the [...]

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  • Page 17

    FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 3: I NST A LL A TION 3-1 3.1 Installing the Fr y er Decathlon 65 S eries fr y e r s y st ems are shipped i n sections. The fryers ar e uncrated, removed from pallets and assembled together. Important aspects durin g assembly include aligning and conn ecting the drain syste m, oil return sy stem, rinse-line [...]

  • Page 18

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 3: INSTA L L A TION 3-2 3.1 Installing the Fr y er (cont.) 3. Connect red/wh ite or red/y ellow wires (Figure 4, left) betw een fryer se ctions being assem bled (Figure 4 , right, a rrow). Oil- return will n ot operate prop erly if thes e wires are not conne cted. NOTE: On systems shipped in three or more[...]

  • Page 19

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 3: INSTA L L A TION 3-3 3.1 Installing the Fr y er (cont.) 9. I nstall the front connecting post on the connect ed cabinets (F igure 8; see fa ctory- installed post s on two-battery fryer secti ons). 10. Complete in stallation of t opcap batter ing strips after the f ront connecting post ha s been install[...]

  • Page 20

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 3: INSTA L L A TION 3-4 3.1 Installing the Fr y er (cont.) DA NGER Fryers must be at room temperature and empty of oil during movement to avoid damage and possib le bodily in jury . DA NGER Hot shortening can c ause sev ere burns. Avoid contact. U nder all circum stances, o il must be remov ed from the fr[...]

  • Page 21

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 3: INSTA L L A TION 3-5 3.2 Gas Connections (cont.) DA NGER If gas odors are d etected, the gas supply MUST be shut off at the main shut-off valv e. The local gas company or FASC should be contacted immediately to rectify the problem. A. The gas supply (service) line must be the same size or g re ater tha[...]

  • Page 22

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 3: INSTA L L A TION 3-6 3.2 Gas Connections (cont.) C. Manual shut-off valve : This gas servic e supplier-installed valve must be installed in the ga s service line ahead of the fryers in the gas stream and in a position where it can be reached quickly in the ev ent of an emer gency. D. Regula tin g Gas P[...]

  • Page 23

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 3: INSTA L L A TION 3-7 3.2 Gas Connections (cont.) I. Flex ible Couplings, Connectors and Casters : 1. If the fr y er is to be installed with flexible couplings and/or quick -disconnect fittings, the installer must use a heavy-duty AGA design-certif ied commercial flexible conne ctor of at least 1" [...]

  • Page 24

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 3: INSTA L L A TION 3-8 3.3.1 Sp ecifications 3.3.1.1 Adj ustments to Different Gas Ty pes Gas Adjustments Gas Type Natural LP Man ifold Pressure † 4" W .C.*/10 m bar* 11" W .C.*/27.5 mbar* Orifice Diamet er Model Spec if ic Model Spec if ic Burner M arking None None Pilot Marking 26N (P/N 8 1[...]

  • Page 25

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 3: INSTA L L A TION 3-9 3.3.2 Gas C onversion Procedures (cont.) Contact facto ry with the fo llowing info rmation when perf orming con versions: • Fr yer Serial Numbe r • Fryer Model Number • Gas T ype • Operating Altitude Conversions c an only be execute d by qualified, factor y-authorized perso[...]

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  • Page 27

    FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4-1 4.1 Initial Sta rt-u p WARNING The on-site supervisor is re sponsible for ensuring that operators are made aware o f the inherent hazards of operating a hot oil fr y ing s y s tem, particularly the aspects of system operation, oil filtration, draining and cleaning procedur es. Cleani[...]

  • Page 28

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 4: FRYER OPE RA TIONS 4-2 4.1.1 Pilot Lighting P rocedures, Electronic Ignition Sy stems Initia l Pilot Lighting : All Frymaster/Dean f ryers are tested, adjusted and cal ibrated to sea level conditions before le aving the factory. Adjustments to assur e proper opera tion of pilot may be necessary on inst[...]

  • Page 29

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 4: FRYER OPE RA TIONS 4-3 4.2 Boil -Out Procedure DA NGER Never leav e the fr yer unattended during the boil-out process. If the boil-out solution boils over, turn the fry er off immediately and let the solution cool for a few minutes before resuming t he process . To lessen t he chance of boil over, t ur[...]

  • Page 30

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 4: FRYER OPE RA TIONS 4-4 4.2 Boil -Out Procedure (cont.) G. The burners will he at the boil-out solution to a simmer. Simmer the solution for approximatel y 45 minutes. W earing protective gloves, scrub the sides of t he frypot and the tubes with the L-shaped Teflon brush, being car eful not to disturb t[...]

  • Page 31

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 4: FRYER OPE RA TIONS 4-5 4.3 Final P reparation WARNING NEVER NEVER NEVER NEVER set a complete block of solid shortening on top of heating tubes. To do so will damage the heating tubes and fry pot, and void the warranty. 4.3.1 Filling Fry er w i th Cooking Oil/Shortening A. When using a liquid shortening[...]

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  • Page 33

    FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 5: FILTR A TION OPER A TI ON 5-1 WARNING Drawings and photos used in this manual are intended to illustrate operational, cleaning and technic al procedures and may no t conform to on-site management operational procedures. 5.1 General Frymaster FPD65 Series gas fryer filter systems come equipped with a filt[...]

  • Page 34

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 5: FILTRAT ION OPER A TION 5-2 5.2.1 A ssembling the Filter (cont.) Assemble t h e filt er as follows: 1. Remove the filte r pan covers. 2. Place the filter leaf asse mbly in the bottom of the filter pan, ensuring t he filter disconnect is properl y placed in the filter pan slot. Support the screen assemb[...]

  • Page 35

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 5: FILTRAT ION OPER A TION 5-3 5.2.1 A ssembling the Filter (cont.) 4. Place the crumb t ray in fil ter pan. 5. Replace the p an covers and install the filter pan into the cabinet. Ensure the connections are fu lly engage d. Ensure the filter pa n opening is directly under the drain tubes to avoid splashi[...]

  • Page 36

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 5: FILTRAT ION OPER A TION 5-4 5.3 Daily Filtration Operat ion WARNING Use caution and wear proper protectiv e clothing. The oil to be filtered is at or near 350°F (177°C). Ensur e all hoses are connected properly and drain handles are in their proper position prior to operating an y switches or v al ve[...]

  • Page 37

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 5: FILTRAT ION OPER A TION 5-5 5.3.2 Filtering Tools Assemble tools to be used for filtering . These a re supplied with the filter starter kit included wit h the frye r/filter sy stem: • Frypot/Filter Br ush– used to clean frypot and filter pan sides and bottom, hea ting tubes, and to dislodge sedime [...]

  • Page 38

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 5: FILTRAT ION OPER A TION 5-6 5.4 Operating the Filter 5.4.1 Filter Operation CA UTION NEVER operate t he filter unit unless coo king oil is at operating temperature [~35 0°F (~177°C) ]. 1. Remove fry baskets fro m frypot. Prior to filtering , skim an y large debris fro m the oil with the fine mesh ski[...]

  • Page 39

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 5: FILTRAT ION OPER A TION 5-7 5.4.1 Filter Operation (cont.) 4. W hen all the oil has drained from the frypot, connect the hose-wand asse mbl y to the disconnect valve in the fryer cabinet. DO NOT ACTIVATE FILTER PUMP UNT IL THE HOSE HAS BEEN PROPERLY CONNECTED. Ensure the hose-disconnect is properl y co[...]

  • Page 40

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 5: FILTRAT ION OPER A TION 5-8 5.4.1 Filter Operation (cont.) 8. Begin the filte rin g p rocess by pulling the y ellow handle to open the oil-return valve (this activate s the filter pump automatically ). 9. Oil will begin to pump from the f ilter pan into the fry pot. Allow the oil to circulate through t[...]

  • Page 41

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 5: FILTRAT ION OPER A TION 5-9 5.4.1 Filter Operation (cont.) 11. After all shortening is pumped back into the frypot, bubbles will form, indicating air in the oil return lines. Allow the shorte nin g to bubble for 15-30 seconds to ensure all shortening is cleared from the return lines. An audible alarm w[...]

  • Page 42

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 5: FILTRAT ION OPER A TION 5-10 5.4.1 Filter Operation (cont.) 14. OPTIONA L EQUIP MENT: Drain-flushes are included on 5-batter y and larger Frymaster FP D65 Series fryers. After filtering fr y pot farthest from the filte r s y stem for 10 minutes, close the oil return valve to stop the filtering pro cess[...]

  • Page 43

    FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 6: P REVENTATIVE MAINTENANCE 6-1 6.1 General DA NGER Never attempt to clean the fry er during the cooking process or w hen the fry pot is filled with hot oil/ shortening. If w ater com es in contact with oil/ shortening heated to cooking temperature, it will cause spatt e ring of the oil/shortening, which c[...]

  • Page 44

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 6: PREVENT A TIVE MAINTENANCE 6-2 6.1.3 Periodic / A nnual The fryer sh ould be inspected and adjusted pe riodically by q ualified service personn el as part of a regular kit chen maintenance program. Frymaster/Dean recommend s that the fryer b e inspected at least ann ually by a Factory Authorized Servic[...]

  • Page 45

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 6: PREVENT A TIVE MAINTENANCE 6-3 6.1.3 Periodic / A nnu al (cont.) • Check filtration sy stem i nteg rit y as follows: − With the filte r pan empty, place each oil return handle, one a t a time, in the " ON" position. Verify that the pump a ctivates and that bubbles appear in the cookin g o[...]

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  • Page 47

    FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 7: TROUBLESH OOTING 7-1 7.1 General DA NGER Hot cooking oil/shortening w ill cau se severe burns. Never att e mpt to move this appliance when f illed with hot cooking oil/short ening or to transf er hot cooking oil/shortening from one cont ainer to another. DA NGER This equipment should be unplugged whe n s[...]

  • Page 48

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 7: TROUBLESHOOTING 7-2 7.2 Pilot Bur ner Malfuncti on (cont.) 3. Check all connections for cleanliness and securit y. C. Pilot flame of proper siz e, but is unstable. Flame wavers and doe s not envelop the thermopile co mpletely at all times. 1. Check for drafts that might be caused b y air conditioning e[...]

  • Page 49

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 7: TROUBLESHOOTING 7-3 7.3 Main Burner M alfunctions (cont.) D. Fryer will not reach the temperature setting and/or runs erraticall y . 1. Incorr ect location of sensor probe or d efective temperatur e sensor. 2. Loose wiring/wire connection E. F r yer shortening temperature cannot be controlled; fryer ru[...]

  • Page 50

    FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 7: TROUBLESHOOTING 7-4 7.4 Wiring Diagram, Main HI L IMI T TO J2 COMPUTER INTERFACE BOARD SPEAKER SOUND GRD 1 COM PUTER INTERFACE BLK WHT A 2 1 BLK WHT 2 1 10 TO CM4-S CO MPUTER 5 34 2 89 7 6 14 12 13 11 15 8 7 6 5 4 3 2 1 4 13 2 5678 RED YEL RED 12 91 0 1 1 91 0 1 2 11 BLK BLK BLK FUSE WHT LINE BLU WHT BLU[...]

  • Page 51

    FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 7: TROUBLESHOOTING 7-5 7.5 Wiring Diagram, Filter 31C 82C 35C 35C 86C 33C 33C 82C P2 T5 T4 T2 30C 27C 8C 9C 120V 12C CIRCUIT 115V INPUT 8051428A TRANSFO RMER/RELAY ASSY OIL RET URN 12 4 3 24V NO NC RH ADD-ON(S ) OIL RETU RN COM NO NO NC NC OIL RETU RN LH ADD-0N(S ) COM COM MOTOR OFF POSITION SHOWN I N FRYER[...]

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  • Page 53

    FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 8: P A R TS LIST 8-1 8.1 Cabinetr y and Related Components[...]

  • Page 54

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 8: PARTS LIST 8-2 8.1 Cabinetr y and Related Components (cont.) ITEM PA RT # COMPONENT 1 810-0357 Caster, 5 " Swivel – W ith Brak e 2 810-0356 Caster, 5 " Swivel – W ithout Brak e 3 823-3248 Support, C aster- Cha nnel Base 4 202-1182 Gusset, Side Panel- Lef t 5 201-1182 Gusset, Side Panel- R[...]

  • Page 55

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 8: PARTS LIST 8-3 8.2 Doors, Topcaps and Related Components[...]

  • Page 56

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 8: PARTS LIST 8-4 8.3 Frypots, Burners and Related Components[...]

  • Page 57

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 8: PARTS LIST 8-5 8.3 Frypots, Burners and Related Components (cont.) ITEM PA RT # COMPONENT 1 823-3948 Frypot- S/S- 65 Series 2 210-5170 Diff user, Burner T ube 3 810-2150 Burner, Right 4 810-2149 Burner, Center 5 810-2151 Burner, Left * 200-2738 Brack et, Burner Mounting * 200-2746 Shield, Burner H eat [...]

  • Page 58

    FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 8: PARTS LIST 8-6 8.4 Component Box Components 1 CM4-S 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 17 ITEM PART # COMPONENT 1 823-3242 Control Box (Inside Non-Filter Fryer Cabinets) 2 210-1364 Plate, Face (For Item #1) 3 200-1322 Bracket, Spark Module 4 200-1326 Cover, Spark Module 5 807-3563 Module, Ignition ([...]

  • Page 59

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 8: PARTS LIST 8-7 8.5 Filter Pan and Related Components[...]

  • Page 60

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 8: PARTS LIST 8-8 8.6 Oil-Drain Components[...]

  • Page 61

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 8: PARTS LIST 8-9 8.6 Oil-Drain Components (cont. ) ITEM PA RT # COMPONENT 1 823-4189 Pipe, Dra in- Right- D6 65 (W ith Oil Dispos al System ) * 823-3441 Pipe, Dra in- Right- D5 65 (No Oil- Disposa l System ) 2 813-0829 Elbow, Dr ain Pipe- 75° 3 809-0884 Nut, Slip J oint- 1- ½" 4 816-0544 O-ring (S[...]

  • Page 62

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 8: PARTS LIST 8-10 8.7 Oil-Return Components Oil Disposal Plumbing (Optiona l) 1[...]

  • Page 63

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 8: PARTS LIST 8-11 8.7 Oil-Return Components (cont.) ITEM PA RT # COMPONENT 3 813-0173 Union, ½" NPT BM 4 813-0003 Tee, ½" N PT BM 5 813-0165 Elbo w, Street ½" N PT BM 90° 6 813-0051 Coupling, ½" NPT BM 7 813-0062 Elbo w, ½" NPT BM 90° 8 810-1003 Valve, B all- Three-W ay ½[...]

  • Page 64

    FRYMA STER FPD65 SERIES GA S FRYERS CHAPTER 8: PARTS LIST 8-12 8.8 Suction Tube, Oil-Retur n Components (cont.) ITEM PA RT # COMPONENT 1 810-0697 Dis connec t, Male- Suct ion T ube * 826-1392 O-ring, S uction T ube Connection (Qty: 5) 2 813-0608 Coupling, F ull- ½" NPT BM 3 823-3188 Suc ti on Man if old Ass em bly 4 813-0062 Elbo w, ½" [...]

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  • Page 66

    Frymaster, 8700 Line Avenue, PO Box 51000, Sh reveport, Louisiana 711 35-1000 Shipping Address: 8700 Line A venue, Shreveport, Louisiana 71106 TEL 1- 318-865-1711 F AX (Parts) 1- 318-688-2 200 FAX (Tech Support) 1-318 -219-7135 PRINTED IN THE UNITED STATES SERVICE HOT LINE 1-800-551- 8633 819-6039 JANUAR Y 2004[...]