Dean 1824 Installation & Operation Manual Download

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24G Series Flatbottom Gas Fryers

Installation & Operation Manual

TABLE OF CONTENTS (CONT.)

Page #

4. FRYER

OPERATIONS

4-1

4.1 Initial

Start-up

4-1

4.2 Boil-Out

Procedure

4-5

4.3 Final

Preparation

4-7

5. CONTROLLER

OPERATION

5-1

5.1

Operating Fryers with Thermatron Controllers

5-1

6. PREVENTATIVE

MAINTENANCE

6-1

6.1 General

6-1

7. TROUBLESHOOTING

7-1

7.1 Pilot

Burner

Malfunction

7-1

7.2

Main Burner Malfunctions

7-2

7.3

Thermatron Controller Calibration

7-3

7.4 Recommended

Spare

Parts

7-4

Summary of Contents for 1824

Page 1: ...ice Association recommends using CFESA Certified Technicians 24 Hour Service Hotline 1 800 551 8633 DECEMBER 2003 PRINTED IN THE USA 8196000 8196000 8196000 8196000 NON CE 24G Series Flatbottom Gas Fryers Installation Operation Manual Models 1824G 2424G ...

Page 2: ... OF ITS AUTHORIZED SERVICE CENTERS AND OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL CONFIGURATION THIS WARRANTY WILL BE VOID FURTHER FRYMASTER DEAN AND ITS AFFILIATES WILL NOT BE LIABLE FOR ANY CLAIMS DAMAGES OR EXPENSES INCURRED BY THE CUSTOMER WHICH ARISE DIRECTLY OR INDIRECTLY IN WHOLE OR IN PART DUE TO THE INSTALLATION OF ANY MODIFIED PART AND OR PART RECEIVED FROM AN UNAUTHORIZED SERV...

Page 3: ...if left soaking in certain shortening material Additional information can be obtained in the filtration manual included with the system WARNING No structural material on the fryer should be altered or removed to accommodate placement of the fryer under a hood Questions Call the Dean Service Hotline at 1 800 551 8633 WARNING Do not bang fry baskets or other utensils on the fryer s joiner strip The ...

Page 4: ... General 2 1 2 3 Principles of Operation 2 3 2 4 Rating Plate 2 3 2 5 Pre Installation 2 4 2 6 Equipment Installed at High Altitudes 2 5 2 7 Air Supply and Ventilation 2 5 2 8 Conversion of Units 2 6 3 INSTALLATION INSTRUCTIONS 3 1 3 1 Installing the Fryer 3 1 3 2 Leg and Caster Installation 3 1 3 3 Leveling the Fryer 3 2 3 4 Gas Connections 3 4 3 5 Adjustments Adaptation to Different Gases 3 8 3 ...

Page 5: ...4 2 Boil Out Procedure 4 5 4 3 Final Preparation 4 7 5 CONTROLLER OPERATION 5 1 5 1 Operating Fryers with Thermatron Controllers 5 1 6 PREVENTATIVE MAINTENANCE 6 1 6 1 General 6 1 7 TROUBLESHOOTING 7 1 7 1 Pilot Burner Malfunction 7 1 7 2 Main Burner Malfunctions 7 2 7 3 Thermatron Controller Calibration 7 3 7 4 Recommended Spare Parts 7 4 ...

Page 6: ...1 2 Ordering Parts Customers may order parts directly from their local Authorized Parts Distributor For this address and phone number contact your maintenance and repair center or call the factory The factory address and phone numbers are on the back cover of this manual To speed up your order the following information is required Model Number Type Serial Number Optional Equipment Item Part Number...

Page 7: ...y to personnel and which may cause damage to your system and or cause your system to malfunction 1 5 Service Personnel 1 5 1 Definitions A Qualified and or Authorized Operating Personnel 1 Qualified authorized operating personnel are those who have carefully read the information in this manual and have familiarized themselves with the equipment functions or have had previous experience with the op...

Page 8: ...zed by Dean to perform service on Dean equipment All authorized service personnel are required to be equipped with a complete set of service parts manuals and stock a minimum amount of parts for Dean equipment A list of Dean Factory Authorized Service Centers FASCs was included with the fryer when shipped from the factory Failure to use qualified service personnel will void the Dean warranty on yo...

Page 9: ... is unnoticed until equipment is unpacked notify freight company or carrier immediately and file a concealed damage claim The claim should be filed within 15 days of date of delivery Be sure to retain container for inspection NOTE Dean Does Not Assume Responsibility for Damage or Loss Incurred in Transit C Move the fryer to the location of installation and install legs and or casters as described ...

Page 10: ... must be lifted during movement to avoid damage to the appliance and bodily injury For moveable installations optional equipment casters must be used Questions Call 1 800 551 8633 2 2 1 Fryer Description Dean 24G Series Flatbottom gas fryers are energy efficient open frypot gas fired units All units are shipped completely assembled with accessories packed inside the frypot All units are adjusted t...

Page 11: ...le 2 3 1 Automatic Safety Features High oil temperature detection to shut off power to the main burners through the solenoid actuated gas valve Combination safety gas valve includes built in pressure regulator and pilot safety Air prover switch built into outlet duct shuts off gas to the burners in the event of blower failure Optional safety switch built into the drain valve prohibits burner ignit...

Page 12: ...ervice 2 Dean 24G Series Flatbottom gas fryers require 120 VAC Non CE or 230VAC CE and are equipped with a 16 3 SJT power cord B Clearances The fryer area must be kept free and clear of all combustibles This unit is design certified for the following installations 1 Commercial installation only not for household use 2 Non combustible floor installation equipped with factory supplied 6 inch 15 cm a...

Page 13: ... Don Mills ONT M3B 2R3 Cleveland OH 44131 National Electrical Code Canadian Electric Code c22 1 part 1 ANSI NFPA 70 Canadian Standards Association American National Standard Institute 178 Rexdale Blvd 1430 Broadway Rexdale ONT M9W 1R3 New York NY 10018 NFPA Standards 96 and 211 c Australian installations must meet National Fire Protection Association 470 Atlantic Avenue AS5601 AG601 Installation C...

Page 14: ...00 F 260 316 C Check air movement during installation Strong exhaust fans in the exhaust hood or in the overall air conditioning system can produce slight air drafts in the room 5 Do not place the fryer s flue outlet directly into the plenum of the hood as it will affect the gas combustion of the fryer 6 Never use the interior of the fryer cabinet for storage or store items on shelving over or beh...

Page 15: ... Pressure 1 mbar 10 2 mm W C 0 4 inch W C 20 mbar 204 mm W C 8 inch W C 1 inch W C 25 4 mm W C 2 5 mbar Heat Input 1 kW 3410 BTU hr 100 BTU hr 0 0293 kW Temperature 0 Celsius 32 Fahrenheit Temperature in degrees Celsius Temperature in degrees Fahrenheit F 32 x 0 555 100 Celsius 212 Fahrenheit 32 x 0 555 ...

Page 16: ...rsonal injury if not secured correctly in a stationary position Drain all oil shortening from fryer before moving Hot oil will splash and cause severe burns upon contact 3 2 Leg and Caster Installation A General 1 Install legs and rear rigid casters near where the fryer is to be used as neither is secure for long transit Unit cannot be curb mounted and must be equipped with the legs and casters pr...

Page 17: ...before installing the casters 3 3 Leveling the Fryer A Place a carpenter s spirit level across the top of the fryer and level the unit front to back If the fryer is not level from side to side a platform or other surface adjustment is needed there are no side to side level adjustments on a fryer equipped with caster leg combinations If a fryer is equipped with legs only side to side level adjustme...

Page 18: ...loor anchor or the manner of installation installing the fryer in an alcove battering to other appliances etc E Installing Optional Swivel Casters 1 Install non locking casters only at the rear of the unit 2 Locking casters must be installed at the front of the unit Locking casters allow the fryer to be locked in position for safe operations 3 Follow the same instructions for leg installations as ...

Page 19: ...re detected the gas supply MUST MUST MUST MUST be shut off at the main shut off valve The local gas company or FASC should be contacted immediately to rectify the problem 3 4 Gas Connections CE REQUIREMENTS Dean 24G Series Flatbottom gas fryers have obtained CE markings for countries and gas categories shown below COUNTRIES CATEGORIES GAS PRESSURE MBAR II2ELL3B P G20 G25 G30 G31 20 50 GERMANY DE I...

Page 20: ...shall be made with a gas connector that complies with national and local codes Quick disconnect devices if used shall likewise comply with national and local codes DANGER The fryer MUST MUST MUST MUST be connected to the gas supply specified on the rating and serial number plate located on the back of the fryer door The gas supply service line must be the same size or greater than the fryer inlet ...

Page 21: ...pes are not clear of all foreign matter the orifices will clog when gas pressure is applied When using thread compound on gas piping use very small amounts and only on male threads Use a pipe thread compound that is not affected by the chemical action of propane LP G31 gases DO NOT apply thread compound to the first two pipe threads doing so will cause clogging of the burner orifices and control v...

Page 22: ...is used it should be installed in accordance with local codes or in the absence of local codes with the appropriate National or European Community CE standards WARNING Use a diluted soap solution to find gas leaks when making new connections B Regulators Gas regulators can be adjusted in the field but no adjustments should be made unless the regulator is out of adjustment or serious pressure fluct...

Page 23: ...ies with local codes or in the absence of local codes with the appropriate National or European Community CE standards 3 Under no circumstances are the connector and the quick disconnect device or its associated piping to be used to limit fryer movement A restraining bracket is provided on the appliance back to prevent the unit from moving from its installed position WARNING Do not attach accessor...

Page 24: ...rating plate When changing gas adaptation must be performed by qualified personnel as defined in Section 1 5 Failure to use qualified personnel will void the Dean warranty DANGER This appliance was configured at the factory for a specific type of gas Converting from one gas type to another requires the installation of specific gas conversion components Switching to a different type of gas without ...

Page 25: ...ing Maximum Opening Maximum Opening 15 mm NOTE Outlet gas pressure must be adjusted strictly within the above requirements 5 to 10 minutes after the appliance is operating For controls and adjustments please refer to the gas valve illustration on page 3 13 Pilot Flame Adjustment Turn the pilot adjustment screw clockwise counter clockwise until the desired flame volume is achieved Orifice size list...

Page 26: ...ed service agency contacted for immediate service 3 7 Gas Conversion Procedures DANGER This appliance was configured at the factory for a specific type of gas Converting from one gas type to another requires the installation of specific gas conversion components Switching to a different type of gas without installing the proper conversion components may result in fire or explosion NEVER ATTACH THI...

Page 27: ...ust orifice gas pressure to the appropriate value listed in the table on page 3 9 by turning the gas valve adjustment screw After adjustment replace the adjustment screw cover Factory MUST be notified so the conversion can be documented and a new rating plate can be sent out When converting from G20 20 mbar to G25 25 mbar or vice versa or G31 37 mbar to G31 50 mbar the following procedures apply C...

Page 28: ...ures After adjustment replace the adjustment screw cover Factory MUST be notified so the conversion can be documented and a new rating plate can be sent out Conversion from one gas family to another i e changing from natural gas to propane requires special components Obtain the necessary components using the tables on page 3 11 Conversions can only be executed by qualified factory authorized perso...

Page 29: ...rect orifice size 3 9 Electrical Connections The fryer when installed must be electrically grounded in accordance with local codes or in the absence of local codes with the appropriate National or European Community CE standards DANGER This fryer is equipped with a three prong grounding plug for protection against electrical shock and must be plugged directly into a properly grounded three prong r...

Page 30: ... then rinse out and wipe dry Also wash any accessories shipped with the unit Close the drain valve completely and replace the drain plug Ensure the temperature sensing probe is adjusted properly see illustration NOTE Current production units are equipped with a probe clamp that holds the sensor bulbs in the proper position Probe adjustment is not normally required Sensor Probe Guard High Limit Tem...

Page 31: ...vibration during shipment and are to be performed only by qualified service personnel These adjustments are the responsibility of the customer and or the dealer and are not covered by the Dean warranty The inlet pipe at the lower rear of the fryer brings incoming gas to the pilot safety control valve then to the pilot and main burners The pilot is located high in the cabinet at the base of the fry...

Page 32: ...NON CE UNITS ONLY 120V 230V Gas Valves Rotate the knob counter clockwise to the ON or PILOT positions Depress and rotate the knob clockwise to turn the gas valve to OFF ON OFF P I L O T O N O F F P I L O T ON OFF P ILOT The pilot is located at the right burner tube at the base of the frypot Use a long match or taper to light the pilot Perform the following steps in sequence before lighting the pil...

Page 33: ...gas valve knob to ON 2 Turn electric power on with the appropriate rocker switch 3 The ignition module will energize the pilot gas supply and the ignitor The ignitor spark will ignite the pilot gas The presence of the pilot flame is then proved by a flame sensor which sends a signal to the main gas supply opening the valve The Thermatron controller controls the fryer after ignition WARNING In the ...

Page 34: ...Empty frypot and pour in cleaning solution concentrate Add water to the upper oil level line scribed in the back of the frypot 2 Thermatron Controller Equipped Fryers Set temperature dial to 225 F 107ºC just above that of boiling water 3 Filtration Boil Mode Equipped Fryers Turn fryer power switch to On Press the fryer reset switch if applicable Turn the boil out switch to On 4 The main burner wil...

Page 35: ...rypot under the drain port to collect the water boil out solution Do not allow water or boil out solution to drain into the filter pan The filter pump is not designed for water operation and will be irreparably damaged 10 Refill the frypot with fresh water and vinegar to neutralize any residual boil out solution Wash all surfaces of the frypot Drain completely and wipe down all surfaces of the fry...

Page 36: ...ug is in place When using a liquid shortening fill the fryer to the appropriate oil level line scribed into the back of the frypot 2 When using a solid shortening cut the shortening into small pieces and pack it into the frypot leaving no air spaces Ensure the sensor probe cover is in place to prevent damage to the sensing bulbs 3 Thermatron Controller with Melt Cycle Option Enabled Set the Therma...

Page 37: ...be manually reset if fryer exceeds high limit setpoint 5 Amp 230VAC Filter Reset Breaker if equipped with filter system Inline between the filter pump and the filter power switch Ensure power is OFF before resetting or replacing FRYER N O F F O Drain Reset Switch Optional Resets drain safety switch after closing drain valve Drain valve must be completely closed prior to resetting switch E R E S T ...

Page 38: ...OFF position when in use HIGH LIMIT RESET Located under control panel Must be manually reset if the fryer exceeds high limit setpoint FILTER RESET BREAKER 7 Amp Circuit Breaker 120VAC or 5 Amp Circuit Breaker 230VAC the breaker is inline between the filter switch and the pump Ensure filter power is off prior to resetting or replacing 5 AMP 115VAC or 2 AMP 230VAC FUSE each fryer circuit is protecte...

Page 39: ... grade cleaner formulated to effectively clean and sanitize food contact surfaces Read the directions and precautionary statements for use Particular attention must be paid to the concentration of cleaner and the length of time the cleaner remains on the food contact surfaces A Remove and wash all removable parts B Clean all exterior surfaces of the cabinet Do not use cleaners steel wool or any ot...

Page 40: ...he burner manifold pressure is in accordance with that specified on the appliance s rating plate Verify that the temperature and high limit probes are properly connected tightened and functioning properly and that the mounting hardware and probe guard are present and properly installed Verify that component box components i e computer controller transformers relays interface boards etc are in good...

Page 41: ...with hot soapy water during the day and with a liquid cleanser designed for stainless steel at the end of each day A Do not use steel wool abrasive cloths cleansers or powders B Do not use a metal knife spatula or any other metal tool to scrape stainless steel Scratches are almost impossible to remove C If it is necessary to scrape the stainless steel to remove any encrusted materials soak the are...

Page 42: ... by an authorized service agent only 7 1 Pilot Burner Malfunctions PROBLEM CORRECTIVE ACTION Pilot will not ignite no evidence of gas at pilot burner 1 Ensure the combination gas valve is in PILOT position and that gas is available at the valve check quick disconnect and or gas line connections 2 Remove pilot gas supply line and check for obstructions Blow out with compressed air if necessary then...

Page 43: ...on no gas pressure at main burner 1 Check that the combination gas valve is ON 2 Check that the pilot is lit and is operating properly 3 Check high limit switch Replace if defective 4 Check air prover switch sail switch as follows Move actuating lever at switch to ensure it is not dragging in the slots use long tool to avoid burns If so bend the arm carefully to clear the obstruction Check the air...

Page 44: ...be should be 1 8 or less to bottom of frypot see illustration on page 4 1 Ensure sensor bulb clamp is present and securely fastened current production models 3 Authorized Service Agent Only Check gas pressure 4 Cooking oil or shortening is of inferior quality or used too long Replace with quality oil or shortening 5 Authorized Service Agent Only May be a short circuit in system Check wiring 7 3 Th...

Page 45: ...3560 High Limit Thermostat Non CE 435 F 224 C 807 3559 Thermocouple Non CE 807 3550 Thermocouple CE 810 1152 Temperature Sensor Probe 106 0882SP Thermatron Interface Board Non CE 120V 807 3566 Thermatron Interface Board CE 208 230V 807 3722 Potentiometer Thermatron Controller 807 3536 Power Switch 807 3574 Boil Out Switch 6 Terminal 807 3579 Fryer Reset Switch Momentary 807 3576 Filter Power Switc...

Page 46: ...uisiana 71135 1000 Shipping Address 8700 Line Avenue Shreveport Louisiana 71106 TEL 1 318 865 1711 FAX Parts 1 318 688 2200 FAX Tech Support 1 318 219 7135 Price 14 00 PRINTED IN THE UNITED STATES SERVICE HOTLINE 1 800 551 8633 819 6000 DECEMBER 2003 ...

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