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® U.S. Registered Trademark
Copyright © 1999 Honeywell International Inc. • All Rights Reserved

INSTALLATION INSTRUCTIONS

69-1004-2

SV9401/SV9402/SV9403, SV9501/

SV9502/SV9503, SV9601/SV9602

SmartValve™

System Controls

APPLICATION

The SV9401/SV9402/SV9403, SV9501/SV9502/

SV9503, and SV9601/SV9602 SmartValve™ System
Controls combine gas flow control and electronic

intermittent pilot sequencing functions into a single unit.
This product family offers several different intermittent

pilot sequences for a wide range of applications. See
Table 1 for specific sequences available. The Q3450 or

Q3480 Intermittent Pilot hardware provides the low
voltage ignition, flame sensor, and pilot burner. This

system is suitable for application in a wide range of
gas-fired appliances including furnaces, rooftop

furnaces, boilers, unit heaters, infrared heaters, space
heaters, water heaters, decorative appliances, and

commercial cooking units. The specific application of the
SmartValve™ System is the responsibility of the

appliance manufacturer. See Table 2 for gas capacity
and thread sizes.

SPECIFICATIONS

WARNING

Fire or Explosion Hazard.
Can cause severe injury, death or property

damage.

The SV9401/SV9402/SV9403; SV9501/SV9502/

SV9503; SV9601/SV9602 provide direct
replacement only. Use the Y8610 to convert

standing pilot systems to electronic ignition
systems.

Ignition Sequences:

See Table 1 for available ignition

sequences.

Body Pattern:

Straight through. See Table 2 for inlet and

outlet specifications.

Capacity:

See Table 2 for available gas flow capacities.
Table 3 describes the acceptable ambient temperature

range for the SV9X01, SV9X02, and SV9X03
SmartValves.

Table 1. Ignition Sequence Description.

All times increase by approximately 20 percent when used at 50 Hz.

Pilot flow stops at end of ignition trial unless pilot lights and proves.

Electrical Ratings:

System Transformer: 40 VA minimum NEMA-rated

transformer. Control systems using SV9601, SV9602,
or other large secondary loads may require a larger

transformer. Refer to the appliance manufacturer
recommendation.

Voltage and Frequency: 24 Vac, 50/60 Hz.

Current draw at 24 Vac: 24V Hot: 1.25A nominal (1.5A

maximum) when igniter is powered.

24V Thermostat: See Table 4.
Electronic Fan Timer Output: 0.1A maximum at 24 Vac.

Output is 8 Vac less than thermostat input voltage at
0.1A draw.

Model

Type

Prepurge (sec)

Ignition Trial Time

Auto Reset Time

SV9401/SV9501/SV9601

Continuous Retry —

90 seconds

5 minutes

SV9402/SV9502/SV9602

15 or 30 seconds

SV9403/SV9503

Single Trial with
Lockout

—

90 seconds

N/A

69-1004-2.fm Page 1 Wednesday, November 5, 2003 10:49 AM

Summary of Contents for LGF

Page 1: ...Gas Pressure Fryer MODELS LGF LGF F LGF FC Installation and Operation Manual Serial Numbers 109576 and higher ...

Page 2: ...OT COVER GLASS BREAKAGE THE ABOVE WARRANTY IS EXCLUSIVE AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED ARE EXCLUDED INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE THIS WARRANTY SHALL APPLY ONLY WITHIN THE CONTINENTAL UNITED STATES ITS TERRITORIES AND POSSESSIONS AND IN CANADA LIMITED NINETY DAY LABOR WARRANTY All labor necessary to repair or replace factory d...

Page 3: ...tem Programming 15 Product Programming 17 Start Up LGF FC 19 Cooking LGF FC 20 Recipes 21 Operation After Gas or Power Outage 23 Normal Shutoff 23 Installation 24 Inspection for Shipping Damage 24 Preparation 24 Location and Clearance 25 Installation Procedure 25 Initial Test and Adjustment 26 Gas Conversion Instructions 27 Maintenance 28 Scheduled Maintenance 28 Safety Pop Valve Procedure 29 Filt...

Page 4: ...ollow recommended safety precautions listed in this manual Below is the safety alert symbol When you see this symbol on your equipment be alert to the potential for personal injury or property damage Safety Signs and Messages The following Safety signs and messages are placed in this manual to provide instructions and identify specific areas where potential hazards exist and special precautions sh...

Page 5: ... contact your local gas supplier for instructions about what to do if you smell gas Post those instructions somewhere near the fryer so that everyone who uses or works near the fryer knows what to do if they smell gas Beware of High Voltage This equipment uses high voltage Serious injury can occur if you or any untrained or unauthorized person installs services or repairs this equipment Always Use...

Page 6: ...yer or the shortening is hot You could be burned Keep The Casters Locked To avoid spilling shortening keep the casters locked If any shortening spills near your fryer clean it up immediately Do Not Overfill The Fryer With Shortening Hot shortening and steam may escape and burn you if you put too much shortening in the fryer Fill the fryer to approximately one inch below the fill marks that are ins...

Page 7: ...ar non skid shoes when working around the fryer or any other equipment that uses shortening Never wear loose clothing such as neckties or scarves while operating your fryer Keep loose hair tied back or in a hair net while operating your fryer Always wear appropriate personal protection equipment during the filtering process to guard against possible injury from hot oil Always wear appropriate pers...

Page 8: ...hildren away from this equipment Children may not understand that this equipment is dangerous for them and others NEVER allow children to play near or operate your equipment Keep Safety Labels Clean and in Good Condition Do not remove or cover any safety labels on your equipment Keep all safety labels clean and in good condition Replace any damaged or missing safety labels Refer to the Safety Labe...

Page 9: ... the fire department near your telephone Know your responsibilities as an Employer Make certain your employees know how to operate the equipment Make certain your employees are aware of the safety precautions on the equipment and in this manual Make certain that you have thoroughly trained your employees about operating the equipment safely Make certain the equipment is in proper working condition...

Page 10: ...Gas Pressure Fryer Introduction 8 Safety Labels ...

Page 11: ...Gas Pressure Fryer Introduction 9 ...

Page 12: ...Gas Pressure Fryer Operation 10 Operation Controls and Indicators Refer to the figure and table below for an explanation of the fryer s controls and indicators ...

Page 13: ...ounts down to 0 Placing the timer switch to the OFF position will stop the buzzer 9 High Limit Reset Switch If shortening inside the pot reaches an unsafe temperature power is automatically removed from the control panel and the gas system shuts off Pressing this switch returns power to the control panel and resets the gas system 10 Gas Control Valve Switch ON Allows gas to flow when the FILTER OF...

Page 14: ...ean any residue or crust formations from the sides and bottom of the pot each time you filter the shortening 5 Add fresh shortening as needed to maintain the proper shortening level TO THE FILL MARK ON THE POT WALL 6 DO NOT HOLD SHORTENING AT HIGH TEMPERATURE when the fryer is not in use If you expect an elapsed time of one hour or more between cooking close the lid and press the 0 button on the L...

Page 15: ...ng as required to reach the fill mark IMPORTANT Before the first cooking operation each day stir the shortening freely while it is heating to provide a balanced shortening temperature for excellent results with the first cooking Failure to do this can result in a crusty skin on the product surface with an undercooked product internally In addition in some cases failure to stir the shortening while...

Page 16: ...f the ON OFF switch 10 When the pointer on the pressure gauge is at zero wait 5 seconds then slowly turn the spin handle counterclockwise to break the seal around the lid The fryer has a locking pin that prevents turning the spin handle until the pressure drops to zero Do not force the spin handle to open the lid 11 Slowly open the lid Failure to use the insulated mitts will result in injury Alway...

Page 17: ...Gas Pressure Fryer Operation 15 LGF FC Operation System Programming Use the following figure and table to set options that apply to each product programs Figure 1 System Programming Sequence ...

Page 18: ...fers to the appliance type you have chosen 8 Press ENTER PROGRAM MELTCYCL YES This command allows you to set the melt cycle option This is normally set to yes if you are using solid shortening The display will show either YES or NO 9 Press TOGGLE CLEAR until the desired option is displayed PROGRAM MELTCYCL X X refers to the melt cycle option chosen 10 Press ENTER PROGRAM GLBLFLTR 0 This command al...

Page 19: ... Fryer Operation 17 Product Programming Use the following figure and table to set a maximum of eight product programs The product programs must be set before cooking can begin Figure 2 Product Programming Sequence ...

Page 20: ... may also display C depending on the system option that is set 8 Press TOGGLE CLEAR and input the cooking temperature for product to be cooked PROGRAM TEMP1 XXX F XXX refers to the cooking temperature you input 9 Press ENTER PROGRAM TEMPCOM1 FLEX TIME This command enables you to select whether or not time is allowed for the fryer to recover from temperature loss while cooking during this stage The...

Page 21: ...lter the shortening filter lockout The filter value displayed may be a previously programmed value 17 Press TOGGLE CLEAR and input the number of fry cycles you want to complete before enabling filter lockout PROGRAM FILTER X X refers to the number of program cycles you want to complete before filtering the shortening 18 Press ENTER PROGRAM PRODUCT 19 If you wish to input more programs proceed by p...

Page 22: ...piece at a time starting with thighs and drumsticks The fryer is designed to accommodate 32 pieces of chicken Failure to use the insulated mitts will result in severe injury Always use the insulated mitts when handling the hot fry basket 5 Lift the basket approximately 2 to 3 inches 6 35 cm above the shortening and shake it This keeps the food from sticking together and causing white spots on the ...

Page 23: ...ing for the day turn the FILTER OFF FRY switch to the OFF position 19 Place the gas control ON OFF switch in the OFF position Recipes Fried Onion Rings 1 Take frozen onion rings from freezer or bread fresh onion rings with Imperial breading 2 Place onion rings into fryer basket 3 Close cover to begin pressure frying 4 Cook for 4 minutes at 350 F for frozen product OR 5 Cook for 3 minutes at 350 F ...

Page 24: ...rying 4 Cook for 9 to 11 minutes at 325 F Whole Turkey 12 to 14 pounds 1 Rinse and bread turkey with Imperial breading 2 Place turkey into fryer basket 3 Close cover to begin pressure frying 4 Cook for 45 to 55 minutes at 300 F Whole Duckling 1 Rinse and bread duck with Imperial breading 2 Place duck into fryer basket 3 Close cover to begin pressure frying 4 Cook for 20 to 25 minutes at 300 F Pork...

Page 25: ... 2 Place egg rolls into basket 3 Close the cover to begin pressure frying 4 Cook for 6 to 8 minutes at 325 F depending on size Operation After Gas or Power Outage The fryer may shut off automatically if the gas supply is interrupted or the power goes out If either of these conditions occur you should perform the following procedure For your safety if the gas supply stops or if the power goes out m...

Page 26: ...isconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of psi 3 5 kPa The fryer 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 psi 3 5 kPa The fryer must be electrically grounded to confo...

Page 27: ...cate your fryer are concrete tile and ceramic Minimum clearance from combustible and non combustible construction is 6 inches from the sides and 6 inches from the flue riser at the rear DO NOT locate your fryer on floors that are wood have rubber mats or are carpeted In Europe no less than 6 15 24 cm from the rear and 0 to the sides of non combustible walls Keep the work area around the fryer free...

Page 28: ...In Canada refer to caster codes CAN 1 6 10 M88 and CAN 1 6 9 M79 7 Turn on the gas at the gas supply valve 8 Check for gas leaks from the gas supply to the fryer gas valve using a soap and water solution If a leak is detected tighten the connection where the leak occurs 9 Connect fryer wiring according to the appropriate wiring diagram in this manual 10 Apply power to the fryer 11 Perform the foll...

Page 29: ...to escape 7 Place the gas control ON OFF switch in the ON position 8 Place the FILTER OFF FRY switch to the FRY position The shortening should begin to heat and begin to reach the fill mark inside the pot Add more shortening as required to reach the fill mark Gas Conversion Instructions To convert the gas system from a Natural Gas to LP Gas application or vice versa contact the BKI Technical Servi...

Page 30: ...acement is required User Lid Gasket Check for unusual wear such as cracks and deformation and pressure leaks Contact authorized BKI service agent if adjustment or replacement is required Daily User Dead Weight Assembly Clean weight and orifices daily and check for wear User Filter Pad Replace filter pad Refer to the procedure in this manual User Condensation Pan Remove and drain User Filter system...

Page 31: ... to use the insulated mitts will result in injury Always use the insulated mitts when handling the arm on the safety valve 1 After the pressure is up during a cooking cycle use the insulated glove to lift the arm on the edge of the safety valve and let some steam escape This will clean the valve 2 Release the lever on the valve and let it slam shut to seal the valve ...

Page 32: ...erly positioned underneath the drain valve Also make certain the filter vat and filter screen is under the main drain valve before starting the filtering process 4 Move the DRAIN handle slowly to the OPEN position so that the shortening starts to flow evenly This is to prevent excessive splashing of hot shortening 5 When the pot is empty place the DRAIN handle in the CLOSED position To refill the ...

Page 33: ...tening position the FILTER OFF FRY switch to OFF to prevent shortening degradation Add new shortening if the fill mark has not been reached LGF 1 Set the FILTER OFF FRY switch to OFF 2 Remove the fryer basket 3 Make certain that the FKF filter unit or portable filter unit filter pad is clean and not torn 4 Position the FKF filter unit or portable filter unit under the main drain valve and make sur...

Page 34: ...id down over the hose nozzle Hold the lid down over the hose nozzle to prevent shortening splashes Position the FILTER OFF FRY switch to FILTER and shortening will automatically pump into the pot After 1 minute hold the hose by the handle and carefully raise the lid to check the level of the shortening Let the filter continue to pump the shortening until the fill mark in the fryer pot is reached o...

Page 35: ...on remove the filter bag screen and pipe connections from the filter vat This must be done before draining the cleaning solution NEVER pump water or detergent through the filter system 11 After 15 minutes slowly open the drain valve Drain the solution into the filter vat and discard 12 Rinse the pot with hot water using the pot brush to remove remaining sediment drain and discard 13 Close the drai...

Page 36: ...is pumped into the pot the filter pad should be replaced immediately If the filter pad is not properly closed breading crumbs will get through the pad opening and clog the pump Ensure that the filter pad is properly closed upon replacement 1 Place the filter screen inside the filter pad 2 Fold the end of the pad and seal with the bag clip ...

Page 37: ... authorized BKI service agent for corrective action Filter System Not Working Uncertain Press the reset button on end of pump and hi limit reset button under control panel If problems persist contact an authorized BKI service agent for corrective action Connections not tight Tighten the connections If problems persist contact an authorized BKI service agent for corrective action Filter valve not o...

Page 38: ...Gas Pressure Fryer Notes 36 Notes ...

Page 39: ...Gas Pressure Fryer Appendix A 37 Appendix A Gas Control Valve Instructions ...

Page 40: ...he SV9401 SV9402 SV9403 SV9501 SV9502 SV9503 SV9601 SV9602 provide direct replacement only Use the Y8610 to convert standing pilot systems to electronic ignition systems Ignition Sequences See Table 1 for available ignition sequences Body Pattern Straight through See Table 2 for inlet and outlet specifications Capacity See Table 2 for available gas flow capacities Table 3 describes the acceptable ...

Page 41: ... available for 3 8 1 2 and 3 4 in NPT pipe See Table 6 NOTE Models with 3 4 in inlet or outlet do not accommodate the adapter kits Table 5 Available Gas Conversion Kits Model Size Inlet X Outlet in Capacity at 1 in wc pressure dropa Minimum Regulated Capacity Maximum Regulated Capacity SV9401 SV9402 SV9403 1 2 x 1 2 NPT 85 ft3 hr 2 3 m3 hr 10 ft3 hrb 0 4 m3 hrb 120 ft3 hr 3 4 m3 hr SV9501 SV9502 S...

Page 42: ...gh above the bottom of the cabinet so it does not get wet during normal cleaning procedures High Humidity or Dripping Water Dripping water can cause the control to fail Never install an appliance where water can drip on the control In addition high ambient humidity can cause the control to corrode and fail If the appliance is in a humid atmosphere make sure air circulation around the control is ad...

Page 43: ...e 1 Do NOT attempt to convert step opening models SV9401P SV9402P SV9403P SV9501P SV9502P SV9503P or SV9601P SV9602P 2 Always change the main and pilot burner orifices when converting from natural to LP gas or from LP to natural gas Follow appliance manufacturer specifications and instructions to assure proper appliance conversion 3 Ignition system controls are factory set for natural and manufact...

Page 44: ...nce vestibule on the gas manifold IMPORTANT Make sure the mounting location protects the control from dripping water and excessive humidity IMPORTANT Make sure the mounting location maximum and minimum ambient temperature are both within the specified acceptable range Install Piping on Control All piping must comply with local codes and ordinances or with the National Fuel Gas Code ANSI Z223 1 NFP...

Page 45: ...arp bends or deform the tubing Do not bend the tubing at the ignition system control after the compression nut is tightened because this can result in gas leakage at the connection 2 Square off and remove burrs from the end of the tubing 3 Unscrew the brass compression fitting from the pilot outlet as shown in Fig 6 4 Slip the fitting over the tubing and slide out of the way as shown in Fig 7 5 Pu...

Page 46: ...a transformer thermostat and other controls as required 2 Connect control circuit to the ignition system control using the keyed plug connector See Fig 8 through 11 Fig 7 Always use new compression fitting Fig 8 SV9401 SV9402 SV9403 SV9501 SV9502 SV9503 SV9601 SV9602 basic wiring diagram CONTROL IGNITER OFF ON OUTLET PRESSURE TAP PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW INLET PRESSURE TAP INL...

Page 47: ...2 3 4 N MOTOR LEADS C X XFMR SEC X EAC N HUM N CIR BLWR CONT COOL HEAT 24 VOLT COMMON 24 VOLT HOT EFT OUTPUT 24 VOLT THERMOSTAT OR PRESSURE SWITCH INDUCER MOTOR HUMIDIFIER DENOTES LINE VOLTAGE WIRING DENOTES LOW VOLTAGE WIRING 2 1 ST9120 NEUTRAL NOTE 3 1 2 CONNECT ONLY IF CONTINUOUS SPEED IS AVAILABLE AND USED CONNECT ONLY IF CONTINUOUS SPEED IS NOT USED CONNECT IF EAC AND HUM TERMINALS ARE AVAILA...

Page 48: ... Check for gas leaks with soap and water solution any time work is done on a gas system CAUTION Equipment Damage Hazard Liquids will damage the gas control Contact with soap and water can damage the control Do not spray soap and water solution on the SmartValve housing Gas Leak Test 1 Paint pipe connections upstream of the ignition system control with rich soap and water solution Bubbles indicate ...

Page 49: ...om the meter reading 2 Convert the flow rate to Btuh as described in Gas Controls Handbook form 70 2602 1 Make sure there is no gas flow through the meter except to the appliance being checked Other appliances must remain off with their pilot lights extinguished Otherwise subtract that usage from the meter reading 3 Compare actual Btuh to the input rate on the appliance nameplate Checking Gas Inpu...

Page 50: ... or counterclock wise to decrease the gas pressure to the burner c Replace the cap screw and tighten firmly to prevent gas leakage 5 If the desired outlet pressure or flow rate cannot be achieved by adjusting the ignition system control check the ignition system control inlet pressure using a manometer at the inlet pressure tap of the ignition system control If the inlet pressure is in the nominal...

Page 51: ...ol it contains no replaceable components Attempted disassembly or repair can damage the ignition system control CAUTION Electrical Equipment Damage Hazard Incorrect wiring can cause equipment damage Do not apply a jumper across or short the thermostat 24V hot or 24V common terminal in the SV9401 SV9402 SV9403 SV9501 SV9502 SV9503 or SV9601 SV9602 wiring harness This can burn out the heat anticipat...

Page 52: ...NITER POWERED PILOT LIGHTS AND FLAME IS SENSED DURING TRIAL FOR IGNITION IGNITER OFF MAIN VALVE OPENS FLAME SIGNAL LOST ELECTRONIC FAN TIMER EFT OUTPUT ENERGIZES THERMOSTAT CALL FOR HEAT ENDS MAIN AND PILOT VALVES CLOSE EFT OUTPUT DE ENERGIZES MAIN AND PILOT VALVES CLOSE EFT OUTPUT DE ENERGIZES FIVE MINUTE RETRY DELAY WAIT FOR FLAME SIGNAL TO DISAPPEAR PILOT VALVE IGNITER REMAIN OFF PILOT VALVE CL...

Page 53: ...EADS TO SmartValve CONTROL MUST MEASURE AT LEAST 19 5 VAC WITH IGNITER POWERED SEE INSET A TO IDENTIFY PROPER LEAD THIS CHECK MUST BE DONE WITH THE SmartValve CONTROL CONNECTED AND IGNITER POWERED CHECK THAT PILOT FLAME MAKES GOOD CONTACT WITH PILOT BURNER FLAME ROD ASSURE PILOT MOUNTING BRACKETS AND PILOT BURNER ARE NOT BENT OR DAMAGED CHECK GAS SUPPLY PRESSURE CHECK PILOT BURNER ORIFICES FOR CON...

Page 54: ...trol application but the specific controls used and the procedures outlined by the manufacturer of your appliance can differ requiring special instructions STOP Read the Warnings Above The pilot flame is lit automatically If the appliance does not turn on when the thermostat is set several degrees above room temperature follow these instructions 1 Set the thermostat to its lowest setting to reset ...

Page 55: ...A on recycled paper containing at least 10 post consumer paper fibers Automation and Control Solutions Honeywell International Inc Honeywell Limited Honeywell Limitée 1985 Douglas Drive North 35 Dynamic Drive Golden Valley MN 55422 Scarborough Ontario M1V 4Z9 ...

Page 56: ...P O Box 80400 Simpsonville S C 29680 0400 USA http www bkideas com Made and printed in the U S A LI0101 0205 ...

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