FPD65, FPHD65, FPLHDC65 Series with Built-In Filtration Frymaster FPHD65 Series Gas Fryers Installation & Operation Manual Please read all sections of this manual and retain for future reference. Frymaster, a member of the Commercial Food Equipment Service Association, recommends using CFESA Certified Technicians.
NOTICE This appliance is intended for professional use only and is to be operated by qualified personnel only. A Frymaster/Dean Factory Authorized Servicer (FAS) or other qualified professional should perform installation, maintenance, and repairs. Installation, maintenance, or repairs by unqualified personnel may void the manufacturer’s warranty. See Chapter 1 of this manual for definitions of qualified personnel.
Improper installation, adjustment, maintenance or service, and unauthorized alterations or modifications can cause property damage, injury, or death. Read the installation, operating and service instructions thoroughly before installing or servicing this equipment. Only qualified service personnel may convert this appliance to use a gas other than that for which it was originally configured. See Chapter 1 of this manual for definition of qualified service personnel.
FPHD65 Series Gas Fryers Installation & Operation Manual TABLE OF CONTENTS Page # 1. INTRODUCTION 1-1 1.1 After Purchase 1-1 1.2 Ordering Parts 1-1 1.3 Service Information 1-1 1.4 Computer Information 1-1 1.5 Safety Information 1-2 1.6 Service Personnel 1-3 2. IMPORTANT INFORMATION 2-1 2.1 Receiving and Unpacking Equipment 2-1 2.2 General 2-2 2.3 Principles of Operation 2-3 2.4 Rating Plate 2-3 2.5 Pre-Installation 2-3 2.6 Air Supply and Ventilation 2-5 2.
FPHD65 Series Gas Fryers Installation & Operation Manual TABLE OF CONTENTS (CONT.) Page # 5. FILTRATION OPERATION 5-1 5.1 General 5-1 5.2 Filtration Preparation 5-1 5.3 Daily Filtration Operation 5-4 5.4 Operating the Filter 5-6 6. PREVENTATIVE MAINTENANCE 6-1 6.1 General 6-1 7. TROUBLESHOOTING 7-1 7.1 General 7-1 7.2 Pilot Burner Malfunction 7-2 7.3 Main Burner Malfunctions 7-2 7.4 Wiring Diagram, Main 7-4 7.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 1: INTRODUCTION 1.1 After Purchase In order to improve service, have the following chart filled in by the Frymaster/Dean Authorized Servicer who installed this equipment. Authorized Servicer Technician/FAS Address Telephone/Fax Model Number Serial Number Gas Type 1.2 Ordering Parts Customers may order parts directly from their local factory authorized servicer.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 1: INTRODUCTION 1.4 Computer Information (cont.) The user is cautioned that any changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment. If necessary, the user should consult the dealer or an experienced radio and television technician for additional suggestions.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 1: INTRODUCTION 1.6 Service Personnel 1.6.1 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 operation of equipment covered in this manual. B. Qualified Installation Personnel 1.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2.1 Receiving and Unpacking Equipment A. Check that the containers are upright. Use an outward prying motion - no hammering - to remove the cartons. Unpack fryers carefully and remove all accessories from the carton and/or frypots. Do not discard or misplace accessories, as they will be needed during final assembly and fryer operation. B. After unpacking, immediately check the equipment for visible signs of shipping damage.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2.2 General Qualified, licensed, and/or authorized installation or service personnel only (as defined in Section 1.6) should perform the following: Installation and service on Frymaster/Dean equipment. Conversion of this appliance from one gas type to another.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2.3 Principles of Operation The incoming gas flows through orifices and is mixed with air in the burners to create the correct ratio for proper combustion. The mixture is ignited at the front end of each heat tube by the pilot light. Internal diffusers slow the flame as it goes through the burner tube. This slower and more turbulent flame gives much better heat transfer to the walls of the tubes, thereby heating the oil better. 2.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2.5 Pre-Installation (cont.) B. Clearances: The fryer area must be kept free and clear of all combustibles. This unit is designcertified 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) adjustable legs or 5-inch (13-cm) casters; 3.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2.6 Air Supply and Ventilation DANGER This appliance must be installed with sufficient ventilation to prevent the occurrence of unacceptable concentrations of substances harmful to the health of personnel in the room in which it is installed. Keep the area around the fryer clear to prevent obstruction of combustion and ventilation airflow as well as for service and maintenance. A. Do not connect this fryer to an exhaust duct. B.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.1 Installing the Fryer Decathlon 65 Series fryer systems are shipped in sections. The fryers are uncrated, removed from pallets and assembled together. Important aspects during assembly include aligning and connecting the drain system, oil return system, rinse-line system (where applicable), oil-return switch wiring harness and fryer cabinets. Slight modifications to connecting hardware may be required when assembling the system.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 3: INSTALLATION Figure 5: Clamp the fryers together to facilitate mounting securing brackets. Figure 6: Attach strip joining the fryer sections. Install screws under the lower edge. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. Figures 7,8: Use screws to attach securing brackets. Ensure the rear bracket screws go through the vertical stiffening channel. Attach the flue cap joiner strip at the back of the frypot.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.1 Installing the Fryer (cont.) DANGER Fryers must be at room temperature and empty of oil during movement to avoid damage and possible bodily injury. DANGER Hot shortening can cause severe burns. Avoid contact. Under all circumstances, oil must be removed from the fryer before attempting to move it to avoid oil spills, and the falls and severe burns that could occur.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.2 Gas Connections (cont.) DANGER If gas odors are detected, the gas supply MUST be shut off at the main shut-off valve. The local gas company or FAS should be contacted immediately to rectify the problem. A. The gas supply (service) line must be the same size or greater than the fryer inlet line. This fryer system is equipped with three 1" (28 mm) female inlets (one inlet per two fryers).
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.2 Gas Connections (cont.) C. Manual shut-off valve: This gas service supplier-installed valve must be installed in the gas service line ahead of the fryers in the gas stream and in a position where it can be reached quickly in the event of an emergency. D. Regulating Gas Pressure: The fryer and shut-off valve must be disconnected from the gas supply during any pressure testing of the system. 1.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.2 Gas Connections (cont.) I. Flexible Couplings, Connectors and Casters: 1. If the fryer is to be installed with flexible couplings and/or quick-disconnect fittings, the installer must use a heavy-duty AGA design-certified commercial flexible connector of at least 1" NPT (with suitable strain reliefs), in compliance with the Standard for Connectors for Movable Gas Appliances, ANSI Z21.69-(latest edition) and Addenda Z21.69a-(latest edition).
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.3.1 Specifications 3.3.1.1 Adjustments to Different Gas Types Gas Adjustments Natural LP 4" W.C.*/10 mbar* 11" W.C.*/27.5 mbar* Orifice Diameter Model Specific Model Specific Burner Marking None None 26N (P/N 810-0811) 16LP (P/N 810-2400) Gas Type Manifold Pressure† Pilot Marking * Gas pressure may vary per fryer model and altitude. Check the rating plate for specific gas pressures.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.3.2 Gas Conversion Procedures (cont.) Contact factory with the following information when performing conversions: Fryer Serial Number Fryer Model Number Gas Type Operating Altitude Conversions can only be executed by qualified, factory-authorized personnel. Pressure flow adjustment (remove cover screw to access) Pilot pressure adjustment (remove cover screw to access) Typical gas valve Regulator Vent Pilot gas supply connection.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.1 Initial Start-up WARNING The on-site supervisor is responsible for ensuring that operators are made aware of the inherent hazards of operating a hot oil frying system, particularly the aspects of system operation, oil filtration, draining and cleaning procedures. Cleaning: New units are wiped clean with solvents at the factory to remove any visible signs of dirt, oil, grease, etc.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.1.1 Pilot Lighting Procedures, Electronic Ignition Systems Initial Pilot Lighting: All Frymaster/Dean fryers are tested, adjusted and calibrated to sea level conditions before leaving the factory. Adjustments to assure proper operation of pilot may be necessary on installation to meet local conditions, low gas pressure, differences in altitude and variations in gas characteristics.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.2 Boil-Out Procedure DANGER Never leave the fryer unattended during the boil-out process. If the boil-out solution boils over, turn the fryer off immediately and let the solution cool for a few minutes before resuming the process. To lessen the chance of boil over, turn the fryer’s gas valve knob to the PILOT position occasionally.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.2 Boil-Out Procedure (cont.) G. The burners will heat the boil-out solution to a simmer. Simmer the solution for approximately 45 minutes. Wearing protective gloves, scrub the sides of the frypot and the tubes with the L-shaped Teflon brush, being careful not to disturb the temperature sensing probes and the high-limit thermostat. H. Do not allow the water level to decrease below the bottom OIL LEVEL line in frypot during boil-out operation.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.3 Final Preparation WARNING NEVER set a complete block of solid shortening on top of heating tubes. To do so will damage the heating tubes and frypot, and void the warranty. 4.3.1 Filling Fryer with Cooking Oil/Shortening A. When using a liquid shortening (cooking oil), fill the fryer to the bottom OIL LEVEL line scribed into the back of the frypot. B.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION WARNING Drawings and photos used in this manual are intended to illustrate operational, cleaning and technical procedures and may not conform to on-site management operational procedures. 5. 1 General Most SUFF/UFF systems use filter paper as the filter medium. Some filter systems can be special ordered with a filter-leaf assembly, which eliminates the need for filter paper.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.3 Filter Preparation On initial installation and before each use, clean the filter: a. remove all loose parts from the filter, b. wash the filter pan and all accessories in hot, soapy water, c. and dry thoroughly. 5. 3.2 Filter Unit Types FILTER PAPER AND HOLD DOWN RING Filter paper is held in place by a hold-down ring. Oil moves through the paper, leaving behind impurities. 5 1. Filter pan. 2. Filter support grid. 4 3.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.2.2 Filter Unit Types (cont.) FILTER LEAF A filter leaf is a fine mesh screen which is reusable and takes the place of disposable paper. Oil moves through the leaf, leaving behind impurities. 1. Filter pan. 2. Filter leaf. 3. Crumb Screen. 4. Caster. A filter unit which utilizes a filter leaf to filter the oil.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.2.3 Assembling the Filter FILTER PAPER AND HOLD DOWN RING 1. Place the support grid in the bottom of filter pan. Support grid properly placed in filter pan. 2. Put one filter paper sheet on top of the support grid. Be sure the paper covers the filter pan bottom and laps two inches onto the pan wall. Ensure filter paper overlaps two inches on all sides and is evenly distributed under the holddown ring. 3.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.2.4 Assembling the Filter (cont.) 4. Sprinkle 8 ounces (227g) of filter powder on the filter sheet. Ensure the powder covers the filter paper evenly. 5. Place the crumb screen in the filter pan. Allow the crumb screen to rest on the top edges of the hold-down ring. Sprinkle the proper amount of filter powder evenly over the paper. Crumb screen properly placed. 6. Return filter pan to cabinet.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.2.5 Assembling the Filter (cont.) FILTER LEAF 1. Remove the filter pan from the fryer by pulling out on the filter pan handle. 2. Remove the crumb basket by lifting it up and out of the filter pan. Be careful not to damage the tubes or connectors in the pan. Pull out on the handle to remove the filter pan. 3. Remove the filter leaf by lifting up on the pickup tube and raising the filter leaf assembly gently out of the filter pan.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.2.6 Assembling the Filter (cont.) 6. Sprinkle 8 ounces (227g) of filter powder on the filter leaf. Ensure the powder covers the mesh evenly. Applying filter powder to filter-leaf. 7. Replace the crumb tray in the pan after filter powder application. Crumb screen properly placed in filter pan. 8. Return the filter pan to the fryer cabinet. Ensure the pickup tube is solidly connected.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.2.7 Installing the Filter 9. Slide the filter inside the fryer cabinet. Ensure the male-female pickup tubes are fully engaged. Ensure the filter pan opening is directly under the center dump tube. The filter pan slides under the fryer (left), connecting with a male connector (right). Ensure that the pickup tube is securely coupled with this connector. Its location may vary based on model. 5.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.3.2 Filtering Tools Assemble tools to be used for filtering. These are supplied with the filter starter kit included with the fryer/filter system: Frypot/Filter Brush - used to clean frypot and filter pan sides and bottom, heating elements, and to dislodge sediment during filtration or oil change. Clean-out Rod (design may vary) - used to dislodge heavy debris in the drain tube (when needed). Filter Powder.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.4 Operating the Filter 5.4.1 Pan Preparation and Operation See Section 6.2.1, Assembling the Filter, and Section 6.2.2, Installing the Filter, for the appropriate filter preparation procedure. For optional filter hose and wand, see Section 6.4.3, Optional Filter Hose and Wand Operation. CAUTION NEVER operate the filter unit unless cooking oil is at operating temperature (~350°F/ ~177°C). 1.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.4.2 Pan Preparation and Operation (cont.) 4. After ensuring the filter pan is correctly positioned under the drain tubes, move the red handle to the open position (right) to drain the frypot into the filter pan. Drain ONLY one frypot at a time. The filter pan is designed to hold the contents of one frypot only. Move the red drain valve handle into the open position. 5.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.4.3 Filter Operation 6. Oil will begin to pump from the filter pan into the frypot. If the frypot tubes, sides and bottom have sediment deposits, clean the frypot with the cleaning brush included with the fryer. Clean beneath and under the burner tubes, using care not to disturb the probes (arrow). Clean all sediment and suspended particles from the burner tubes and frypot as the oil begins to circulate.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.4.4 Filter Operation (cont.) 9. After all oil is pumped back into the frypot, bubbles will form, indicating air in the oil return lines. Allow the oil to bubble for 1015 seconds to ensure all oil is evacuated from the return lines. Push the yellow handle to close the oil return valve and deactivate the filter pump (see Step 5 above for additional reference).
DECATHLON SERIES GAS FRYERS CHAPTER 5: UNDER FRYER FILTER (SUFF/UFF) FILTRATION 5.4.5 Filter Operation (cont.) 12. Do not allow crumbs to accumulate in the crumb tray. The crumb tray MUST be emptied into a fireproof container at the end of frying operations EACH DAY (see DANGER statement below). Empty the filter pan crumb tray into a fire-proof container at the end of frying operations each day. DO NOT ALLOW CRUMBS TO ACCUMULATE IN TRAY.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.5 Optional Filter Hose and Wand Operation Some frying systems come equipped with an optional filter hose, wand, and toggle switch to facilitate the removal of debris from the frypot. The hose attaches to a quick-disconnect in the fryer cabinet. 1. Ensure the oil is at operating temperature (~350°F/~177°C). Turn the fryer off and open the fryer drain valve. Allow the oil to drain into the filter pan.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.6 Hose and Wand Operation (cont.) 5. The oil will start to flow immediately into the frypot. Keep the wand inside the frypot at all times while the filter pump is activated. Yellow 6. Rinse debris from the frypot into the filter pan with the wand. 7. When cleanup is complete, press the wand/disposal switch to OFF, close the drain valve (red handle) and close the wand/disposal valve with the blue handle. Red 8.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 6: PREVENTIVE MAINTENANCE 6.1 General DANGER Never attempt to clean the fryer during the cooking process or when the frypot is filled with hot oil/shortening. If water comes in contact with oil/shortening heated to cooking temperature, it will cause spattering of the oil/shortening, which can result in severe burns to nearby personnel. Any equipment works better and lasts longer when maintained properly and kept clean. Cooking equipment is no exception.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 6: PREVENTIVE MAINTENANCE 6.1.3 Periodic/ Annual The fryer should be inspected and adjusted periodically by qualified service personnel as part of a regular kitchen maintenance program. Frymaster/Dean recommends that the fryer be inspected at least annually by a Factory Authorized Servicer as follows: Inspect fryer cabinet inside and out, front and rear, for excessive oil build-up and/or oil migration. Verify that burners and associated components (i.e.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 6: PREVENTIVE MAINTENANCE 6.1.3 Periodic/ Annual (cont.) Check filtration system integrity as follows: With the filter pan empty, place each oil return handle, one at a time, in the "ON" position. Verify that the pump activates and that bubbles appear in the cooking oil/shortening of the associated frypot. Close all oil return valves (i.e., place all oil return handles in the "OFF" position).
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 7: TROUBLESHOOTING 7.1 General DANGER Hot cooking oil/shortening will cause severe burns. Never attempt to move this appliance when filled with hot cooking oil/shortening or to transfer hot cooking oil/shortening from one container to another. DANGER This equipment should be unplugged when servicing, except when electrical circuit tests are required. Use extreme care when performing such tests.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 7: TROUBLESHOOTING 7.2 Pilot Burner Malfunction (cont.) 3. Check all connections for cleanliness and security. C. Pilot flame of proper size, but is unstable. thermopile completely at all times. Flame wavers and does not envelop the 1. Check for drafts that might be caused by air conditioning equipment or make-up air apparatus. Turn air-moving equipment off and recheck the pilot. 7.3 Main Burner Malfunctions A.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 7: TROUBLESHOOTING 7.3 Main Burner Malfunctions (cont.) D. Fryer will not reach the temperature setting and/or runs erratically. 1. Incorrect location of sensor probe or defective temperature sensor. 2. Loose wiring/wire connection E. Fryer shortening temperature cannot be controlled; fryer runs at high-limit temperature. 1. Defective temperature probe; Call Factory Authorized Servicer.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 7: TROUBLESHOOTING 7.
FRYMASTER FPHD65 SERIES GAS FRYERS CHAPTER 7: TROUBLESHOOTING 7.
Frymaster, 8700 Line Avenue, Shreveport, Louisiana 71106 TEL 1-318-865-1711 PRINTED IN THE UNITED STATES FAX (Parts) 1-318-688-2200 SERVICE HOTLINE 1-800-551-8633 FAX (Tech Support) 1-318-219-7135 819-6445 FEB 13
