LJS 24G Series Flatbottom Gas Fryers Installation & Operation Manual Models 1824G, 2424G and 1824/2424G Systems with Built-In Filtration Frymaster/Dean, a member of the Commercial Food Equipment Service Association, recommends using CFESA Certified Technicians.
Please read all sections of this manual and retain for future reference. This product has been certified as commercial cooking equipment and MUST be installed by professional personnel as specified. Installation, maintenance and repairs should be performed by your FRYMASTER FACTORY AUTHORIZED SERVICE CENTER. DANGER Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other cooking appliance.
DANGER The front ledge of the fryer is not a step. Do not stand on the fryer. Serious injury can result from slips or contact with the hot oil. 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. WARNING No structural material on the fryer should be altered or removed to accommodate placement of the fryer under a hood.
LJS 24G Series Flatbottom Gas Fryers INSTALLATION & OPERATION MANUAL TABLE OF CONTENTS Page # 1. DESCRIPTION AND SPECIFICATIONS 1-1 2. PRE-INSTALLATION 2-1 3. INSTALLATION INSTRUCTIONS 3-1 4. INITIAL STARTUP 4-1 5. DAILY OPERATION 5-1 6. PREVENTATIVE MAINTENANCE 6-1 7.
LJS 24G SERIES FLATBOTTOM GAS FRYERS CHAPTER 1: DESCRIPTION AND SPECIFICATIONS The LJS 24G Series gas fryers are energy-efficient, gas-fired units, design-certified by the American Gas Association and the National Sanitation Foundation, and manufactured to their basic performance and application specifications. All units are shipped completely assembled, with all accessories packed inside the frypot. All units are adjusted, tested, and inspected at the factory prior to crating for shipment.
1.3 RATING PLATE The rating plate can be found inside the fryer door. Information on this plate includes the model and serial numbers, as well as BTU/hr output of the burners, outlet gas pressure in inches W.C., and configuration: natural or propane gas. Rating plate data is essential for proper unit identification, communicating with the factory or requesting special parts and/or information. 1.4 SERVICE PROBLEMS Call 1-800-551-8633 for the location of your nearest Factory Authorized Service Center.
1.7 COMPUTER INFORMATION This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. While this device is a verified Class A device, it has been shown to meet the Class B limits. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment.
1.9 SERVICE PERSONNEL 1.9.1 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.
LJS 24G SERIES FLATBOTTOM GAS FRYERS CHAPTER 2: PRE-INSTALLATION 2.1 GENERAL A. Installation of any gas-fired equipment should be performed by qualified personnel. B. A manual gas shut-off valve must be installed in the gas supply line between the appliance(s) and the main gas supply for safety and ease of future service. 2.2 CLEARANCES The appliance area must be kept clear of all combustibles. Each unit is design-certified for the following installations: 1. Commercial use only (not for household use). 2.
2.3 STANDARDS (cont.) E. NFPA Standards #96 and #211 (latest edition) National Fire Protection Association 470 Atlantic Avenue Boston, MA 02110 WARNING Local building codes will usually not permit a deep fat fryer with an open tank of hot oil to be installed immediately next to an open flame of any type, whether a broiler or the open burner of a range. Check local codes before beginning installation. 2.
LJS 24G SERIES FLATBOTTOM GAS FRYERS CHAPTER 3: INSTALLATION INSTRUCTIONS 3.1 UNPACKING Check that the container is upright. Use outward prying - no hammering - to remove the carton. Inspect the fryer(s) for visible damage. If such damage has occurred, do not refuse shipment, but contact the carrier and file the appropriate freight claims. FRYMASTER/DEAN FRYERS EQUIPPED WITH LEGS ARE FOR PERMANENT INSTALLATION. FOR MOVEABLE OR PORTABLE INSTALLATION, FRYMASTER/DEAN OPTIONAL EQUIPMENT CASTERS MUST BE USED.
3.5 GAS CONNECTION The gas supply (service) line must be the same size or greater than the inlet line of the appliance. LJS 24G Series gas fryers use a 3/4" NPT (Schedule 40) inlet; however, the gas supply lines must be sized to accommodate all the gas-fired equipment that may be connected to that supply. Consult your contractor, gas company or supplier, or other authorized agent for inspection and installation. Sealant on all pipe joints must be resistant to LP gas. 3.5.
3.5.5 Flexible Couplings, Connectors If the unit 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. The connector must be at least 3/4" NPT (with suitable strain reliefs) in compliance with the Standard for Connectors for Movable Gas Appliances, ANSI Z21.69-1987 (or latest edition).
3.7 SYSTEM INSTALLATION INSTRUCTIONS 1. This system consists of a 2424G fryer with a built-in filter and an additional fryer that will be attached to it. The additional fryer may be a 24G, an 1824G or a 2424G. If the additional fryer is an 1824G, the 18inch frypot must be in the outside position, as shown in the illustration below. These frypots must mate. These frypots must mate. 24 18 24 24 Filter Unit 24 Figure 1. Retainer latches securing filter pan.
3.7 SYSTEM INSTALLATION INSTRUCTIONS (CONT.) 6. Slowly push the two systems together. Adjust the front casters to align the cabinets vertically. Ensure the drainpipe and the slipnut (lower set of arrows in Fig. 4) are aligned and that the drain-flush lines (upper set of arrows in Fig. 4) are aligned. Also ensure the oil-return line flange and fittings on the rear of the fryer are aligned. Connect the fittings, but do not tighten the connections.
3.7 SYSTEM INSTALLATION INSTRUCTIONS (CONT.) 11. Prior to performing start-up, ensure the drainpipe connected during assembly is not blocking either frypot drain. Shine a flashlight into the drains. The illustration below shows from left to right, an unblocked drain, a partially blocked drain, and a completely blocked drain. If partially or completely blocked, loosen the drain slip-nuts and reposition the drain tube. Both drains should appear as the left-most picture below. Drain unblocked.
LJS 24G SERIES FLATBOTTOM GAS FRYERS CHAPTER 4: STARTUP AND OPERATING PROCEDURES 4.1 CLEANING Note: All procedures should be performed as instructed in the current LJS Operations Manual. In the absence of the LJS Operations Manual, the following procedures are offered as a temporary solution. New units are wiped clean with solvents at the factory to remove dirt, oil, and grease remaining after the manufacturing process, and then coated with light oil.
4.2 INITIAL STARTUP LJS 24G Series gas fryers are tested, adjusted, and calibrated before leaving the factory. Adjustments to assure proper operation may be necessary upon installation to meet local conditions, low gas pressure, differences in altitude, variations in gas characteristics and to correct possible problems caused by rough handling or vibrations during shipment. Gas component adjustments after receiving the fryer should be performed by authorized service personnel.
4.3 ELECTRONIC SPARK IGNITION WARNING NEVER USE A MATCH OR TAPER TO LIGHT THIS IGNITION SYSTEM! 1. Turn off the electric power. 2. Turn the gas valve dial to "OFF", wait 5 minutes, and then turn the dial to "ON". 3. Set the thermostat to the desired temperature. If the frypot is filled with water (Non-KFC co-branded locations), set thermostat to 200°F (93°C); if filled with oil, set thermostat to 350°F (177°C). 4. Turn the fryer power switch on. 5.
4.4 ADJUSTING BURNERS (cont.) Loosen screw to adjust burner damper for optimum flame. Figure 2: Burner damper adjustment on burner tubes. NOTE: In KFC co-branded locations, boil out is NOT ALLOWED. Use KFC approved procedure. 4.4.1 Boil Out Procedure (Non-KFC Co-Branded Locations Only) 1. Turn off the fryer and drain the shortening from the fryer in accordance with filtering instructions. 2. Remove the Sensor Probe Guard (Figure 1, Page 4-1) and place it in the bottom of the fryer during boil-out. 3.
4.4.1 Boil Out Procedure (cont.) 8. Continue the boil-out procedure for 20 minutes. Brush the sides and bottom of the frypot with an approved brush to remove deposits. Add hot water if needed to maintain the proper liquid level in the fryer. 9. Turn the fryer off and drain the boil-out solution into an appropriate container and discard. DO NOT DRAIN BOIL-OUT SOLUTION INTO THE FILTER SYSTEM. IRREPARABLE DAMAGE WILL OCCUR AND ALL APPLICABLE WARRANTIES WILL BE VOIDED. 10. Refill the frypot with clean water.
4.6 FINAL PREPARATION Before starting operation, turn the Thermatron controller to the desired shortening temperature, wait for the temperature to stabilize, and then check with a high-quality immersion thermometer. WARNING NEVER MOVE A FRYER FILLED WITH HOT LIQUID. DO NOT GO NEAR THE AREA DIRECTLY OVER THE FLUE OUTLET WHEN THE MAIN BURNERS ARE OPERATING. ALWAYS WEAR OIL-PROOF, INSULATED GLOVES WHEN WORKING WITH HOT OIL. ALWAYS DRAIN HOT OIL INTO A METAL CONTAINER...
LJS 24G SERIES FLATBOTTOM GAS FRYERS CHAPTER 5: DAILY OPERATION/FILTRATION 5.1 OPENING At opening, check the fryer for: 1. Combination or main gas valve "OFF". 2. Power Switch "OFF" (If so equipped). For lighting the fryer, see Section 4.2 (Section 4.3 if equipped with Electronic Ignition). 5.2 GENERAL OPERATIONS STATEMENT See the LJS Operations Manual for operating instructions prior to using the LJS 24G Series gas fryer.
5.4 FILTER PREPARATION 1. Assemble the filter pan, ensuring all components are clean and dry. When assembling the filter pan, follow LJS Operations: Shortening – Filtering, or the following in absence of LJS instructions: 2. Remove filter-pan lid. Filter pan with lid removed. 3. Place the filter leaf assembly in the bottom of the filter pan. Ensure the pick-up tube goes to the right side of the pan (when viewed from front).
5.4 FILTER PREPARATION (cont.) 5. Place the crumb tray inside filter pan, in the proper position. Place crumb tray in filter pan prior to replacing lid. 6. Replace the filter pan lid. Ensure pick-up tube emerges through hole in pan lid. Ensure pick-up tube emerges through hole in pan lid. 7. Ensure filter system hose connection is properly attached to the filter leaf connection prior to activating filter pump. 8. See Section 5.5 for filtering instructions.
5.5 FILTERING INSTRUCTIONS WARNING THE ON-SITE SUPERVISOR IS RESPONSIBLE FOR ENSURING THAT OPERATORS ARE MADE AWARE OF THE INHERENT DANGERS OF OPERATING A HOT OIL FILTER SYSTEM, PARTICULARLY ASPECTS OF OIL FILTRATION, DRAINING, AND CLEANING OF THE FILTER. The Flatbottom 24G Fryer System is equipped with the Under Fryer Filter (UFF). For optimum system performance, do the following: a. Use high-quality oil or shortening. b. Filter daily or even more frequently if cooking is heavy.
5.5 FILTERING INSTRUCTIONS (cont.) G. Clean the filter pan thoroughly and ensure all components are completely dry. H. Follow directions outlined in Section 5.4Filter Preparation, pages 5-2 – 5-3. Ensure filter pan and all components are clean and dry before installing filter leaf assembly and crumb tray. 5.6 FILTER OPERATION 1. Turn the fryer OFF and allow the oil to cool for a minimum of 10 minutes before draining oil into filter pan. 2.
5.6 FILTER OPERATION (cont.) 5. Move the oil-return handle from left to right to open the oil-return line. The filter pump will activate. LJS 24G oil-return handle location. 6. If the filter pump does not activate when the oil-return handle is opened, check the circuit breaker to see if it needs resetting. If the circuit breaker cannot be reset, see page 510 for filtration system troubleshooting. 7.
5.6 FILTER OPERATION (cont.) NOTE: If using solid shortening, ensure the oil-return lines are clear before turning off the pump motor. Hang all flexible hoses up to drain after filtration is complete. Failure to due so increases the likelihood of solidified shortening clogging the lines. 11. Immediately empty the crumb tray into a fireproof container after filtering is complete. Clean and dry the filter pan and associated components as instructed in Sections 5.4 and 5.5.
5.7 Disassembling/Assembling and Cleaning the Magnum Filter Leaf LJS 24G Series fryers with UFF filtration come equipped with a filter leaf, which eliminates the need for filter paper. The filter leaf requires specific cleaning and assembly procedures. In the absence of cleaning and disassembly/reassembly instructions shipped with the filter leaf, use the following procedure: 2 4 1 1 3 5.7.
5.7.2 Cleaning the Filter Leaf Assembly Clean the two seal frame pieces, screens and grid using a good quality degreaser and hot water from a spray nozzle. The groove in the seal frame pieces can be cleaned with the edge of a Scotch-Brite or similar cleaning pad. At each scheduled boil out, disassemble the filter leaf as described in Section 5.7.1 and place in the frypot filled with boil-out solution. Follow the boil-out procedure in Section 4.4.
5.9 FILTER TROUBLESHOOTING The problems and possible solutions covered are those most commonly encountered. Pump won't start. Pump stops during filtering process. Motor is hot. Pump stops and motor is cool. Pump starts and abruptly stops. y y y y Return valve not fully open. Tripped circuit breaker. Incorrect or no line voltage. Failed return valve microswitch. y Allow motor to cool for at least 45 minutes and then press thermal overload switch on motor. Also reset the 7-amp circuit breaker.
LJS 24G SERIES FLATBOTTOM GAS FRYERS CHAPTER 6: PREVENTATIVE MAINTENANCE Consult the LJS Operations Manual for cleaning and maintenance instructions. Cleaning and maintenance instructions in this chapter are intended for temporary use as a guide in absence of the LJS Operations Manual. 6.1 Daily Fryer Maintenance Follow procedures in LJS Operations: Shortening – Filtering, Daily Fryer Maintenance section. 6.2 Daily Remove and wash all removable parts in hot, soapy water.
6.4 Periodic 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 Service Technician 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. gas valves, pilot assemblies, ignitors, etc.
6.4 Periodic (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).
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LJS 24G SERIES FLATBOTTOM GAS FRYERS CHAPTER 7: TROUBLESHOOTING FACTORY APPROVAL MUST BE OBTAINED PRIOR TO ANY WARRANTY WORK BEING DONE OR DEAN CANNOT BE HELD RESPONSIBLE. The following procedures must be performed by Factory Authorized Service Technicians, and are provided as an aid to expedite troubleshooting and repair of LJS 24G Series frying systems. 7.1 PILOT BURNER MALFUNCTIONS PROBLEM CORRECTIVE ACTION Pilot will not ignite; no evidence of gas at pilot burner.
7.2 MAIN BURNER MALFUNCTIONS PROBLEM Main burner will not come on even though air blower is in operation; no gas pressure at main burner. Air blower is not operating, although power is present at the fryer. Signs of excessive frypot temperature; Oil quickly becomes discolored. CORRECTIVE ACTION 1. Check that the combination gas valve is ON. 2. Check that the pilot is lit and is operating properly. 1.
7.3 INDICATOR LIGHTS (cont.) When turning the power switch "ON" and resetting the safety (reset) switch, check for the following: LIGHT INDICATION GREEN LIGHT/POWER SWITCH IS "ON" PROBABLE CAUSE 1. The drain valve is open. 2. The drain switch is defective. CORRECTIVE ACTION GREEN LIGHT/SAFETY (RESET) SWITCH IS "OFF" 1. Ensure the drain valve is completely closed, and then turn the reset switch to "ON". 2.
TEMP.
7.5.
7-6 FUSE 2 AMP J BOX WHT 75C BLK 77C BLK 76C BLK WHT WHT 74C T2 T8 T3 P2 P1 T3 T2 P2 P1 JUNCTION BOX P/N 8073642 COVER PLATE P/N 8073643 FUSE P/N 8073592 FUSE HOLDER 8071321 P/N 8071420 HEAT TAPE - 25 WATT T4 T8 P/N 8102097 MOTOR BLUE 83C RELAY PN 8073611 BLK 81C BLK 79C FOR CHANGE OF ROTATION INTERCHANGE LEADS T5 AND T8 ON THE MOTOR T5 T4 LOW VOLTAGE SHOWN 24V 120V T5 HIGH VOLTAGE SHOWN CIRCUIT BREAKER 7 AMP-120V PN 8073538 5 AMP-480V PN 8073538 CB BLK 78C WHT 82C NO NC 2
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Frymaster/Dean, 8700 Line Avenue, PO Box 51000, Shreveport, Louisiana 71135-1000 Shipping Address: 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 819-5758 MARCH 2004
