FPD65 Series with Built-In Filtration Frymaster FPD65 Series Gas Fryers Installation & Operation Manual PARTS LIST INCLUDED Frymaster, 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. NOTICE This appliance is intended for professional use only and is to be operated by qualified personnel only. A Frymaster/Dean Factory Authorized Service Center (FASC) 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.
DANGER 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.
FPD65 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.
FPD65 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 7.5 Wiring Diagram, Filter 7-5 8. PARTS LIST 8-1 8.
FRYMASTER FPD65 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 Service Technician who installed this equipment. Authorized Service Technician/FASC Address Telephone/Fax Model Number Serial Number Gas Type 1.2 Ordering Parts Customers may order parts directly from their local factory authorized service center.
FRYMASTER FPD65 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 FPD65 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 FPD65 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 FPD65 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 FPD65 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 FPD65 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 FPD65 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 FPD65 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 FPD65 SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.1 Installing the Fryer (cont.) 3. Connect red/white or red/yellow wires (Figure 4, left) between fryer sections being assembled (Figure 4, right, arrow). Oil-return will not operate properly if these wires are not connected. NOTE: On systems shipped in three or more sections, additional wiring between cabinets will exist. Ensure all wires are connected before completing cabinet assembly. 4.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.1 Installing the Fryer (cont.) 9. Install the front connecting post on the connected cabinets (Figure 8; see factory-installed posts on two-battery fryer sections). 10. Complete installation of topcap battering strips after the front connecting post has been installed (Figure 9). Figure 8. Installing front connecting post on connected fryer sections.
FRYMASTER FPD65 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 FPD65 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 FASC 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 FPD65 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 FPD65 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 FPD65 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 FPD65 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 FPD65 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 FPD65 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 FPD65 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 FPD65 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 FPD65 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 FPD65 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 Frymaster FPD65 Series gas fryer filter systems come equipped with a filter-leaf assembly, which eliminates the need for filter paper. Filter powder is used to enhance the filtration process. 5.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.2.1 Assembling the Filter (cont.) Assemble the filter as follows: 1. Remove the filter pan covers. Filter pan with covers removed. 2. Place the filter leaf assembly in the bottom of the filter pan, ensuring the filter disconnect is properly placed in the filter pan slot. Support the screen assembly by holding the supply pipe during installation. The bracket fits into a slot in the pan. 3.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.2.1 Assembling the Filter (cont.) 4. Place the crumb tray in filter pan. Crumb screen placement in filter pan. 5. Replace the pan covers and install the filter pan into the cabinet. Ensure the connections are fully engaged. Ensure the filter pan opening is directly under the drain tubes to avoid splashing hot oil. The fryer is ready for filtering. The filter pan slides under the fryer (above), connecting with a slip fitting (right).
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.2.2 Disassembling/Assembling and Cleaning an Optional Filter Leaf Follow these steps to clean a leaf-style filter: 2 4 1 1 3 Filter Leaf Disassembly/Assembly Grasp the seal frame near each corner at the locking tab (1) and pull frame apart The seal frame will separate into two pieces. Separate the top and bottom screens (2 & 3) and remove the grid (4). Assemble in reverse order.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 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.
FRYMASTER FPD65 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 tubes, and to dislodge sediment during filtration or shortening change. Clean-Out Rod– used to dislodge heavy debris in the drain tube (when needed).
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.4 Operating the Filter 5.4.1 Filter Operation CAUTION NEVER operate the filter unit unless cooking oil is at operating temperature [~350°F (~177°C)]. 1. Remove fry baskets from frypot. Prior to filtering, skim any large debris from the oil with the fine mesh skimmer. Use extreme caution, as oil is at or near operating temperature [~350°F (~177°C)]. Use a metal scraper to gently remove debris from frypot walls above shortening level.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.4.1 Filter Operation (cont.) 4. When all the oil has drained from the frypot, connect the hose-wand assembly to the disconnect valve in the fryer cabinet. DO NOT ACTIVATE FILTER PUMP UNTIL THE HOSE HAS BEEN PROPERLY CONNECTED. Ensure the hose-disconnect is properly connected before proceeding. Remove the frypot wire rack prior to rinsing frypot.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.4.1 Filter Operation (cont.) 8. Begin the filtering process by pulling the yellow handle to open the oil-return valve (this activates the filter pump automatically). Begin the filtering process by pulling yellow handle to open oil return valve. Leave the drain valve (red handle) open during the filtering process. 9. Oil will begin to pump from the filter pan into the frypot.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.4.1 Filter Operation (cont.) 11. After all shortening is pumped back into the frypot, bubbles will form, indicating air in the oil return lines. Allow the shortening to bubble for 15-30 seconds to ensure all shortening is cleared from the return lines. An audible alarm will sound, indicating that the frypot is full. Push the yellow handle to close the oil return valve and deactivate the filter pump.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 5: FILTRATION OPERATION 5.4.1 Filter Operation (cont.) 14. OPTIONAL EQUIPMENT: Drain-flushes are included on 5-battery and larger Frymaster FPD65 Series fryers. After filtering frypot farthest from the filter system for 10 minutes, close the oil return valve to stop the filtering process. Do not refill the frypot. Close the drain valve (red handle) on the frypot being filtered. Ensure all other valves (red and yellow handles) are closed.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 6: PREVENTATIVE 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 FPD65 SERIES GAS FRYERS CHAPTER 6: PREVENTATIVE 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 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.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 6: PREVENTATIVE 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 FPD65 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 FPD65 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 FPD65 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 Authorized Service Agent.
FUSE BLU BLU GND WHT WHT BLK FUSE WHT BLK WHT LINE VOLTAGE 7-4 1 2 SPEAKER 1 2 RED BLU J3 TO J2 COMPUTER INTERFACE BOARD 1 2 TO CM4-S COMPUTER CM4-S COMPUTER 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 BLU 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 HI LIMIT BLU 24 VAC GAS VALVE IGNITER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 J2 BLK BLK BLK YEL COMPUTER INTERFACE BOARD 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 RED YEL RED SOUND GRD A BLK WHT 12V LINE YEL BLU RED
7-5 BLK CB 30C WHT P1 41C MOTOR 82C 12C 8C 27C FOR CHANGE OF ROTATION INTERCHANGE LEADS T5 AND T8 ON THE MOTOR P1 P2 T3 T2 P2 T8 T3 T2 T4 T8 T5 T4 LOW VOLTAGE SHOWN 24V 120V T5 HIGH VOLTAGE SHOWN 5 AMP-480V CIRCUIT BREAKER 7 AMP-120V WHT#1 BLK INPUT 115V CIRCUIT COM 82C 33C NC NO 2 4 OIL RETURN LH ADD-0N(S) 86C 1 3 OIL RETURN TRANSFORMER/RELAY ASSY NC NO 33C MICRO SWITCH SHOWN IN OFF POSITION OIL RETURN FRYER COM 35C 31C NC NO OIL RETURN RH ADD-ON(S)
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 8: PARTS LIST 8.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 8: PARTS LIST 8.1 Cabinetry and Related Components (cont.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 8: PARTS LIST 8.2 Doors, Topcaps and Related Components 1 3 FPD665 Shown 2 12 11 10 9 8 13 4 5 7 6 ITEM 1 * 2 3 PART # 824-1183 824-1184 824-1185 824-0951 4 5 6 7 8 9 10 * * 11 12 13 * * Not Illustrated 200-1301 200-1185 210-1424 810-2105 809-0918 809-0191 810-0066 810-1105 200-3663 809-0266 810-0179 200-1675 809-0413 COMPONENT Topcap, 4-Battery Topcap, 3-Battery Topcap, 2-Battery Wireway, Control Panel (Component Box: See Section 8.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 8: PARTS LIST 8.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 8: PARTS LIST 8.3 Frypots, Burners and Related Components (cont.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 8: PARTS LIST 8.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 8: PARTS LIST 8.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 8: PARTS LIST 8.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 8: PARTS LIST 8.6 Oil-Drain Components (cont.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 8: PARTS LIST 8.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 8: PARTS LIST 8.7 Oil-Return Components (cont.
FRYMASTER FPD65 SERIES GAS FRYERS CHAPTER 8: PARTS LIST 8.8 Suction Tube, Oil-Return Components (cont.
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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 819-6039 SEPT 2008
