Oil Conserving Fryer (OCF30)™ GAS FRYERS Installation & Operation Manual Frymaster, a member of the Commercial Food Equipment Service Association, recommends using CFESA Certified Technicians. 24-Hour Service Hotline 1-800-551-8633 www.frymaster.com E-mail: service@frymaster.
NOTICE IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART FOR THIS MANITOWOC FOOD SERVICE EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART PURCHASED DIRECTLY FROM FRYMASTER DEAN, OR ANY OF ITS AUTHORIZED SERVICERS, AND/OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL CONFIGURATION, THIS WARRANTY WILL BE VOID.
DANGER Adequate means must be provided to limit the movement of this appliance without depending upon the gas line connection. Single fryers equipped with legs must be stabilized by installing anchor straps. All fryers equipped with casters must be stabilized by installing restraining chains. If a flexible gas line is used, an additional restraining cable must be connected at all times when the fryer is in use.
OCF30™ Series Gas Fryers Installation and Operation Manual TABLE OF CONTENTS CHAPTER 1: General Information 1.1 Applicability and Validity ........................................................................................................ 1-1 1.2 Safety Information ................................................................................................................... 1-1 1.3 Controller Information ..............................................................................................
CHAPTER 5: Preventive Maintenance 5.1 Fryer Preventive Maintenance Checks and Service................................................................. 5-1 5.2 Daily Checks and Service ........................................................................................................ 5-1 5.2.1 Inspect Fryer for Damage ............................................................................................. 5-1 5.2.2 Clean Fryer Cabinet Inside and Out .................................................
OCF30™ SERIES GAS FRYER CHAPTER 1: GENERAL INFORMATION 1.1 Applicability and Validity The OCF30™ Series Gas Fryer, with SMART4U® technology, has been approved by the European Union for sale and installation in the following EU countries: AT, BE, DE, DK, ES, FI, FR, GB, IE, IT, LU, NL, NO, PT and SE. This manual is applicable to and valid for all OCF30™ Series Gas Fryers sold in Englishspeaking countries, including those in the European Union.
1.3 Controller Information FCC COMPLIANCE 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.
1.5 Equipment Description OCF30™ Series high-efficiency gas fryers employ a unique infrared burner system that uses up to 43% less energy to cook the same volume as conventional open-burner fryers. Models in this series include FPGL variants. These models have a built-in FootPrint Pro filtration system located under the leftmost fryer in a battery.
QUALIFIED INSTALLATION PERSONNEL Qualified installation personnel are individuals, firms, corporations, and/or companies which, either in person or through a representative, are engaged in and are responsible for the installation of gasfired appliances. Qualified personnel must be experienced in such work, be familiar with all gas precautions involved, and have complied with all requirements of applicable national and local codes.
When ordering parts, the following information is required: Model Number: Serial Number: Type of Gas or Voltage: Item Part Number: Quantity Needed: Service information may be obtained by contacting your local FAS/Distributor. Service may also be obtained by calling the Frymaster Service Department at 1-800-551-8633 or 1-318-865-1711 or by e-mail: service@frymaster.com.
OCF30™ SERIES GAS FRYER CHAPTER 2: INSTALLATION INSTRUCTIONS 2.1 General Installation Requirements Qualified, licensed, and/or authorized installation or service personnel, as defined in Section 1.7 of this manual, should perform all installation and service on Frymaster equipment. Conversion of this appliance from one type of gas to another should only be performed by qualified, licensed, and/or authorized installation or service personnel as defined in Section 1.7 of this manual.
One of the most important considerations of efficient fryer operation is ventilation. Make sure the fryer is installed so that products of combustion are removed efficiently, and that the kitchen ventilation system does not produce drafts that interfere with burner operation. The fryer flue opening must not be placed close to the intake of the exhaust fan, and the fryer must never have its flue extended in a “chimney” fashion.
2.1.3 Electrical Grounding Requirements All electrically operated appliances must be grounded in accordance with all applicable national and local codes, and, where applicable, CE codes. In the absence of local codes, the appliance must be grounded in accordance with National Electrical Code, ANSI/NFPA 70, or the Canadian Electrical Code, CSA C22.2, as applicable. All units (cord connected or permanently connected) should be connected to a grounded power supply system.
1. Adequate means must be provided to limit the movement of fryers without depending upon the gas line connections. If a flexible gas hose is used, a restraining cable must be connected at all times when the fryer is in use. The restraining cable and installation instructions are packed with the flexible hose in the accessories box that was shipped with your unit. DANGER Do not attach an apron drainboard to a single fryer. The fryer may become unstable, tip over, and cause injury.
2.4 Connection to Gas Line DANGER Before connecting new pipe to this appliance, the pipe must be blown out thoroughly to remove all foreign material. Foreign material in the burner and gas controls will cause improper and dangerous operation. DANGER The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of the system at test pressures in excess of ½ PSI (3.45 kPa, 13.84 inches W.C.
* For distances of more than 20 feet (6 m) and/or more than 4 fittings or elbows, increase the connection by one pipe size. The OCF30™ Series gas fryer has received the CE mark for the countries and gas categories indicated in the table below. NOTE: The nominal heat input (QN) is 21kW except for AT, DE, LU and category 3P/B, which is 23kW. NOTICE- Australia Only The air pressure switch on the combustion blower should read: Full Vat units-122pa (0.5 inches W.C.) and for Split Vat units-180pa (0.72 inches W.
NOTE: Some fryers are configured for a rigid connection to the gas supply line. These units are connected to the gas supply line at the rear of the unit. When using thread compound, use very small amounts on male threads only. Use a pipe thread compound that is not affected by the chemical action of LP gases (Loctite™ PST56765 Sealant is one such compound). DO NOT apply compound to the first two threads.
5. Check the programmed temperature thermostat setting. (Refer to chapter 4 K3000 Computer Instructions) for the setpoint programming instructions for your particular controller.) 2.5 Converting to another Gas Type DANGER This appliance was configured at the factory for a specific type of gas. Converting from one type of gas to another requires the installation of specific gas-conversion components. Conversion instructions are included with conversion kits.
CE GAS CONVERSION INSTRUCTIONS 1. Between G20- and G25-type Natural Gas, adjust the gas pressure at the regulator. (Refer to the CE Standard Burner Manifold Gas Pressure Chart.) Do not change the orifice. 2. Between a 2nd family (G20 or G25) and a 3rd family gas (G30 Butane or G31 Propane): a. Change the orifices. b. Adjust the manifold pressure. 3. Remove the old rating plate and return to Frymaster.
2. Close fryer drain-valve(s). 3. Clean and fill frypot(s) to the bottom oil level line with cooking oil. (See Equipment Setup and Shutdown Procedures in Chapter 3.) 2.7 Installing the JIB Cradle Open the fryer door (typically the far right door) and remove the cross brace used for shipping support by removing the four screws (see Figure 1). Install the JIB cradle shipped in the accessories pack with the screws that were removed in the cross brace removal step (see Figure 2).
™ OCF30 SERIES GAS FRYER CHAPTER 3: OPERATING INSTRUCTIONS FINDING YOU WAY AROUND THE OCF30™SERIES GAS FRYER Flue Cap Basket Hanger Top Cap Control Panel (3000 Controller shown) Bezel JIB reset button Drain Handle Filter Pan FootPrint Pro Built-in Filtration Unit Optional JIB (See Sec. 3.4) TYPICAL CONFIGURATION (FPGL230 SHOWN) NOTE: The appearance of your fryer may differ slightly from that shown depending upon the configuration and date of manufacture.
3.1 Controller Operation and Programming This fryer is equipped with either 3000 or CM3.5 controllers (illustrated below). Fryers with 3000 controllers should refer to the 3000 Controller Manual 819-6872 for the controller programming and operating procedure. For CM3.5 controllers refer to the separate Frymaster Fryer Controllers User’s Manual furnished with your fryer for the specific controller operating instructions. 3000 CONTROLLER CM3.
1. Fill the frypot with cooking oil to the bottom OIL LEVEL line located on the rear of the frypot. This will allow for oil expansion as heat is applied. Do not fill cold oil any higher than the bottom line; overflow may occur as heat expands the oil. 2. Ensure that the power cord(s) are plugged into the appropriate receptacle(s). Verify that the face of the plug is flush with the outlet plate, with no portion of the prongs visible. 3.
Left Viewing Ports are behind the motor housings. Right Viewing Ports The optimum burn is a bright orange-red glow. If a blue flame is observed, or if there are dark spots on a burner face, adjust the air gas mixture as follows: On the side of the blower housing opposite the motor is a plate with a locking nut. Loosen the nut enough to allow the plate to be moved, then adjust the position of the plate to open or close the air intake opening until a bright orange-red glow is obtained.
3.4 Optional Oil Attendant™ Automatic Top-Off When the Oil Attendant™ top-off oil system is in place on the fryer, oil is continually topped off in the frypots from a reservoir in the cabinet. The reservoir holds a 35 pound box of oil. In a typical operation this will last approximately two days before changing. Components of the system are annotated at the right (see Figure 1). NOTE: The system is intended to top off the frypots, not fill them.
3.4.2 Routine Oil Changes When the oil reservoir level is low, the controller displays TOPOFF OIL EMPTY in the left display and CONFIRM in the right display. Press (CONFIRM). Some procedures may differ from photos shown. Follow manufactures instructions for changing the JIB. If using solid shortening see Appendix B in the rear of this manual for instructions. 1. Open the cabinet and slide the JIB from 2. Remove the cap and pour any remaining oil in the the cabinet (see Figure 3).
OCF30™ SERIES GAS FRYERS CHAPTER 4: FILTRATION INSTRUCTIONS WARNING The on-site supervisor is responsible for ensuring that operators are made aware of the inherent hazards of operating a hot oil filtering system, particularly the aspects of oil filtration, draining and cleaning procedures. 4.1 Preparing the Built-In Filtration System for Use The FootPrint Pro filtration system allows the oil in one frypot to be safely and efficiently filtered while the other frypots in a battery remain in operation.
2. Inspect the filter pan connection fitting to ensure that both O-rings are in good condition (see Figure 2). 3. Then in reverse order, place the metal filter screen in the center of the bottom of the pan, then lay a sheet of filter paper on top of the screen, overlapping on all sides (see Figure1). If using a filter pad, ensure the rough side of the pad is up and lay the pad over the screen, making sure that the pad is in between the embossed ridges of the filter pan.
4.2 Filtration A 3000 controller prompts the user when to filter on the OCF30™ fryer. After a preset number of cook cycles the controller displays filter now? alternating with YES NO. Follow the instructions on page 1-12 in the controller manual 819-6872. If NO is selected or a cook cycle is started, the controller will prompt again soon to filter the oil. On demand filtration is used to manually start a filter. See page 1-11in the controller manual 8196872 for the filter menu.
DANGER NEVER attempt to clear a clogged drain valve from the front of the valve! Hot oil will rush out creating the potential for severe burns. DANGER DO NOT hammer on the drain valve with the cleanout rod or other objects. Damage to the ball inside will result in leaks and will void the Frymaster warranty. 4. After the oil has drained from the frypot and when prompted, rotate the filter handle towards the “I” to start the pump and begin the filtering process.
WARNING Use caution and wear appropriate safety equipment when resetting the filter pump reset switch. Resetting the switch must be accomplished with care to avoid the possibility of a serious burn caused by careless maneuvering around a drain tube and around a frypot. DANGER The crumb tray in fryers equipped with a filter system must be emptied into a fireproof container at the end of frying operations each day. Some food particles can spontaneously combust if left soaking in certain shortening material.
2. At each scheduled boil-out, disassemble the leaf filter assembly and place in the frypot being boiled out. Follow the boil-out procedure in Section 5.3.2 of this manual. 3. Allow all filter assembly components to air dry or thoroughly dry with clean towels before reassembling. Reassembly 1. Place the two outer screens together and align their edges (see illustration below). 2. Insert the screens into one of the frame halves (it doesn’t matter which one).
not available, allow the oil to cool to 100°F (38°C), then drain the oil into a METAL stockpot or similar METAL container. DANGER Draining and filtering of cooking oil must be accomplished with care to avoid the possibility of a serious burn caused by careless handling. The oil to be filtered is at or near 350°F (177°C). Ensure all hoses are connected properly and drain handles are in their proper position before operating any switches or valves.
OCF30™ SERIES GAS FRYERS CHAPTER 5: PREVENTIVE MAINTENANCE 5.1 FRYER PREVENTATIVE MAINTENANCE CHECKS AND SERVICE DANGER The crumb tray in fryers equipped with a filter system must be emptied into a fireproof container at the end of frying operations each day. Some food particles can spontaneously combust if left soaking in certain shortening material. DANGER Never attempt to clean fryer during the cooking process or when the frypot is filled with hot oil.
WARNING Never drain water into the filter pan. Water will damage the filter pump. There are no periodic preventive maintenance checks and services required for your FootPrint Pro Filtration System other than daily cleaning of the filter pan with a solution of hot water and detergent. If you notice that the system is pumping slowly or not at all, verify that the filter pan screen is on the bottom of the filter pan, with the paper on top of the screen.
5.3.2 Boiling Out the Frypot After the fryer has been in use for a period of time, a hard film of caramelized oil will form on the inside of the frypot. This film should be periodically removed by following the boil out procedure that follows. 1. Before switching the fryer(s) ON, close the frypot drain valve(s), then fill the empty frypot with a mixture of cold water and detergent. Follow instructions on detergent container when mixing. 2.
5.4 MONTHLY CHECKS AND SERVICE 5.4.1 Check 3000 Set Point Accuracy (This check applies only to units equipped with 3000 or CM3.5 Controllers.) 1. Insert a good-grade thermometer or pyrometer probe into the oil, with the end touching the fryer temperature-sensing probe. 2. When the 3000 controller display shows “DROP” or the CM3.
5.6 Annual/Periodic System Inspection This appliance should be inspected and adjusted periodically by qualified service personnel as part of a regular kitchen maintenance program. Frymaster recommends that a Factory Authorized Servicer inspect this appliance at least annually as follows: 5.6.1 Fryer Inspect the cabinet inside and out, front and rear for oil. Verify that the flue opening is not obstructed by debris or accumulations of solidified oil.
Verify that all O-rings and seals are present and in good condition. Replace O-rings and seals if worn or damaged. Check filtration system integrity as follows: Verify that filter pan cover is present and properly installed. 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 oil of the associated frypot. Close all oil return valves (i.e., place all oil return handles in the OFF position).
2. Remove the three fasteners that secure the blower motor assembly to the blower housing, and separate the two components (see Figure 2). Remove these fasteners. Figure 2 3. Wrap the motor with plastic wrap to prevent water from entering it. Spray degreaser or detergent on the blower wheel and the blower housing. Allow it to soak for five minutes. Rinse the wheel and housing with hot tap water, then dry with a clean cloth (see Figure 3). Wrap the motor and wires with plastic wrap or a plastic bag.
Left viewing port is behind motor (NOTE: Blower shield omitted for clarity.) Right Viewing Port Figure 4 The air/gas mixture is properly adjusted when the burner manifold pressure is in accordance with the applicable table on page 2-7 and the burners display a bright orange-red glow. If a blue flame is observed, or if there are dark spots on a burner face, the air/gas mixture requires adjustment. On the side of the blower housing opposite the motor is a plate with one or two locking nuts.
OCF30™ SERIES GAS FRYERS CHAPTER 6: OPERATOR TROUBLESHOOTING 6.1 Introduction This chapter provides an easy reference guide to some of the common problems that may occur during the operation of your equipment. The troubleshooting guides that follow are intended to help you correct, or at least accurately diagnose, problems with your equipment. Although the chapter covers the most common problems reported, you may encounter problems that are not covered.
6.2 Troubleshooting Fryers 6.2.1 Controller and Heating Problems PROBLEM PROBABLE CAUSES A. Press the ON/OFF switch to turn the controller on. B. Verify that the fryer is plugged in and that the circuit breaker is not tripped. C. Call your FAS for assistance. A. Controller not turned on. No display on the B. No power to fryer. controller. C. Failed controller or other component Controller displays IS VAT FULL? YES NO after a filtration.
6.2.2 Error Messages and Display Problems PROBLEM PROBABLE CAUSES Controller displays low temp or LO. Frypot temperature has dropped more than 30°F (17°C) lower than setpoint in idle mode or 45°F (25°C) in cook mode. This display is normal for a short while if a large batch of frozen product is added to the frypot or if the fryer is not heating properly. If the issue persists call your FAS for assistance. Controller displays Hot hi-1.
6.2.3 Basket Lift Problems PROBLEM PROBABLE CAUSES CORRECTIVE ACTION Apply a light coating of Lubriplate™ or similar lightweight white grease to the rod and bushings. Basket lift rods need lubrication. Basket lift movement is jerky and/or noisy. 6.2.4 Filtration Problems PROBLEM Fryer filters after each cook cycle. Filter menu functions won’t start. Controller displays WAIT FOR Filter. Filter pump won’t start or pump stops during filtering. Filter Pump runs, but oil return is very slow.
One vat doesn’t top off. Controller displays TOPOFF OIL EMPTY / CONFIRM A. Filter error exists. B. Service required error exists C. Solenoid, pump, pin issue, RTD or ATO issue. A. Clear filter error properly. If problem persists call your FAS for assistance. B. Call your FAS for assistance. C. Call your FAS for assistance. Fill top off system with oil and press the S (CONFIRM) button. Top off system out of oil. 6.2.
LIMIT FAILURE alternating with DISCONNECT POWER with an alert tone during testing. The test is cancelled at any time by turning the fryer off. When the fryer is turned back on, it returns to the operating mode and displays the product. 1. Press and hold the check (9) button until MAIN MENU is displayed followed by PRODUCT SETUP. 2. Press the left arrow (W) button until TECH MODE is displayed. 3. Press the check (9) button. 4. Enter 3000. 5. Press the left arrow (W) button until HI LIMIT TEST is displayed.
OCF30™ SERIES GAS FRYER APPENDIX A: JIB Preparation with Solid Shortening Option 1. Open right door of fryer and remove brace in JIB cabinet. 2. Position melter in front of cabinet. Loosen bracket on left side of melter, if necessary, to ease placement in the cabinet. 3. Use the provided screws to attach the melter to existing holes in the interior rails of the fryer cabinet on both sides. See figures 1 and 2. 4. Plug in the black connector to the outlet box shown in figure 3.
OCF30™ SERIES GAS FRYER APPENDIX B: Solid Shortening Melter Use Reset oil reservoir system • Ensure shortening melter is on. • Fill melter with shortening. • Allow 2-3 hours for solid shortening to melt. DO NOT attempt to use the top off system with unmelted oil in the top off system. The low oil reservoir display will come on if the fryer calls for oil before the shortening in the melter is liquid.
OCF30™ SERIES GAS FRYER APPENDIX C: BULK OIL INSTRUCTIONS C.1.1 Bulk Oil Systems Bulk oil systems have large oil storage tanks, typically located in the rear of the restaurant, that are connected to a rear manifold on the fryer. Some are waste only systems, while others are both waste and fresh oil. Waste oil is pumped from the fryer, via the fitting located on the bottom, to the disposal tanks and fresh oil is pumped from the tanks, thru the fitting located on the top, to the fryer (see Figure 1).
The OCF™ fryers, equipped for use with bulk oil systems, use an onboard fresh oil jug typically supplied by the bulk oil vendor. Remove the cap and insert the standard fitting into the jug with the metal cap resting on the lip of the jug. The oil is pumped in and out of the jug through the same fitting (see Figure 3). WARNING Do not add HOT or USED oil to a JIB Figure 3 Operating the Bulk-Oil Equipped Fryer Bulk Oil Rocker Panel JIB Empty Reset Press after refilling JIB with Add Oil button.
5. Pull the oil disposal valve and the pump will engage and empty the filter pan to the waste oil tank. The Waste Full light on the rocker panel will illuminate if the tank is full. 6. Filling with fresh oil? See Fill Vat from Bulk below. If not, switch to Normal Mode at rocker panel C.1.4 Fill Vat from Bulk Tank 1. Ensure vat is empty and the drain valve is closed. 2. At the rocker panel, switch to Bulk Mode. 3. Open the return valve on the empty tank. Press the Add Fresh Oil button.
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