21 20 LITER GAS FRYER FFA3200 INSTALLATION AND SERVICING.

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1 21 20 LITER GAS FRYER FFA3200 INSTALLATION AND SERVICING

2 20 ALL ANVIL EQUIPMENT COMES WITH A ONE YEAR WARRANTY ON COMPONENTS AND DEFECTIVE WORKMANSHIP.

3 19 20 LITER GAS FRYER INSTALLATION AND SERVICING INSTALLATION AND SERVICING OF 20 LITER GAS FRYER MODEL: FFA3200

4 1 DESCRIPTION 18 MODEL DESCRIPTION POWER (BTU) JET SIZE (mm) FFA LITER GAS FRYER ,2 FEATURES Multifunction gas controller incorporating: a manual gas cock; pressure regulator; automatic pilot safety valve and a millivolt operator regulator. Pilot light, manually lit and hooded. Thermopile supplying millivolt current to automatic pilot safety and operator regulator. Thermocouple safety cutoff. Control thermostat with a range of 60 C-190 C (140 F-375 F). Safety thermostat with a cutoff of 230 C (445 F). There are three cast iron burners which heat three tubes running through the stainless steel frypot. The jets are located in the manifold which runs along the bottom of burners. Diffusers within the tubes distribute the heat evenly. The pilot light is located between the second and third burner and has a hood which directs the flame to the left and right. The pilot serves two purposes; igniting the burners and heating the thermocouple. Both the thermopile and thermocouple are located adjacent to the pilot on and they all share a mounting bracket. When the thermocouple is heated it generates a millivolt current which operates the pilot safety cutoff and the operator regulator. The pilot cutoff is a normally open switch and if the pilot flame should go out the gas supply to the pilot will be cut off. This operates independently the manual gas cock. The safety thermostat also relies on current from the thermocouple. When the temperature reaches 230 it will cut off. It then has to be reset by pressing the red button below the control thermostat once the fryer has cooled off.

5 17 2 INSTALLATION Parts which have been sealed by the manufacturer are pre-set and do not require adjustment by the installer. Remove all packaging material and protective film before installing. This appliance may only be installed by an LP gas installer registered with the LPGASA. The appliance must be installed with the requirements of SANS and any fire department regulation and/or local bylaws applicable to the area. If in doubt check with the relevant authority before undertaking the installation. Upon completion of the installation you are required to fully explain and demonstrate to the user the operational details and safety practices applicable to the appliance and the installation. POSITIONING The unit must be level and all four of the adjustable legs must be in contact with the floor so that it is stable and cannot tilt in any direction. The unit must be installed on a fire proof floor. It the floor is wooden, arrangement must be made to comply with local fire prevention regulations by covering in a suitable non-combustible material. There must also be a minimum clearance of 100mm between the rear and sides of the unit and any surfaces in proximity must be made of, or clad in, noncombustible material. THIS APPLIANCE MUST NOT BE USED IN BASEMENTS OR ROOMS LESS THAN 15 CUBIC METRES IN VOLUME. (TYPICALLY 2.6M SQUARE)

6 3 VENTILATION 16 This fryer requires adequate ventilation and should ideally be located under an extractor hood. The flue discharges from the top of the fryer at a height of 1.2m and there should be a minimum clearance of 600mm between the top of the top of the flue and any overhanging objects. The flue should not be obstructed in any way and there must never be any connection between the flue and an extractor hood or any kind of channeling directing the exhaust gasses. GAS SUPPLY This fryer is designed for use with LPG at a pressure of 2.8kPa. There must be sufficient pressure in the gas supply line to supply the full gas rate without a significant drop in pressure. In the case of insufficient gas pressure, the size of the supply hoses should never be reduced to increase pressure. Pipework should never be smaller than the size of the gas inlet on the fryer. (size?) Regulators used with this appliance must comply to SANS 1237 and be approved by the LPGASA. Only regulators certified for operation at 2.8kPa must be used on these appliances. //checking with a gas meter etc.// //measuring, fitting sizes, regulation etc.// CONNECTION TO THE GAS SUPPLY Only LPG hoses that comply with SANS or BS 3212 may be used with this appliance. A gas cock must be incorporated in the supply pipe and fitted close to the unit and it must be readily accessible in case the gas needs to be turned off in the event of an emergency or for general operation or servicing. //Connector sizes etc.//

7 15 4 CONNECTING THE FRYER TO THE GAS REGULATOR Check O rings and neoprene seals on the regulator. 1. Support the regulator with one hand while aligning the regulator bullnose (threaded part) with the threaded gas outlet on the cylinder valve. 2. Screw regulator hand-wheel ANTI-CLOCKWISE (LEFT-HAND THREAD) into gas outlet. 3. Tighten regulator hand-wheel as tight as possible by hand only. 4. DO NOT USE TOOLS OR LEVERS TO TIGHTEN. 5. When connecting the regulator to the gas cylinder, avoid undue twisting of the flexible hose. Open cylinder valve by turning gas stop cock anti-clockwise. //instructions for fitting stop cock// 6. Make sure that all connections are gas tight by brushing with a soapy solution or liquid detergent (a gas leak will form bubbles). If bubbles form, close cylinder valve and hand tighten all fittings again. //what to do if leak persists//

8 5 GAS PRESSURE ADJUSTMENT 14 The required gas pressure for this fryer is... Before commissioning, the gas pressure must be checked. The pressure test point is located in the burner manifold. Remove the bolt closing this hole and then connect a suitable gas pressure test gauge to this point. Turn on the main gas supply and then light the fryer according to the user instructions. If the supply pipes contain air then the lighting procedure may have to be repeated. Wait at least 3 minutes before relighting the burners. Set thermostat to (what temperature?) Adjust the pressure regulator mechanism on the multi-function controller by turning the regulator screw clockwise to increase pressure or anti-clockwise to reduce pressure. Re-check the pressure after 15 minutes. Turn the burners and pilot off according to the user instructions before removing the pressure gauge from the manifold. Replace the bolt closing the pressure test hole in the manifold. (Seal the thread and test for leaks?)

9 13 6 PILOT ADJUSTMENT The pilot adjustment screw is located under a cover screw adjacent to the pilot outlet. Once the screw is removed the pilot flame can be adjusted using a small flat screwdriver. Turn the pilot adjustment screw counterclockwise to increase the size of the pilot flame or clockwise to reduce it. The flame should be about 20mm from either side of the hood. If the flame is too large it will make it will be excessively noisy. Once the adjustment is done the pilot adjustment cap (screw) must be replaced. SERVICE, MAINTENANCE AND CONVERSION Before servicing or moving the fryer it must be allowed to cool to room temperature and the oil must be drained out. REMOVAL AND CLEANING OF BURNERS The burners should be cleaned regularly to maintain their best performance. This can be done using a wire brush and a metal broach to clean out the burner orifices. The burners have to be removed to be cleaned. REMOVING THE BURNERS Each burner can be removed separately. There are two bolts secured to the top of the burners which fit into keyed slots in the plate above the burner assembly from which they are suspended. The bolts do not need to be loosened before removal. The burners should be able to lift easily and when the bolt heads are aligned with the large part of the key hole they can be pushed back slightly. The burner must then be lifted slightly further to clear the jet mounting from the hole at the bottom of the air intake. Repeat the procedure for the other two burners and reverse the procedure to replace the burners. CLEANING THE JETS The jets would not get clogged by smoke the way the burners would but might still need occasionally cleaning. The jets can be unscrewed from the manifold with an open ended 8mm spanner. Clean the orifice by blowing it out or using a wood splinter or fine wire. Sharp metal objects or reamers can distort the orifice and cause the jet to malfunction.

10 7 DISMANTLING PILOT BURNER ASSEMBLY 12 The pilot burner mounting also has the thermopile and thermocouple attached to it. To remove any of these components the burners on either side will first have to be removed. 1. First undo the compression nut at the bottom of the pilot burner using a 13mm spanner and withdraw the pilot gas pipe. The pilot jet will also come out when the compression nut is removed. 2. The nearest component to the front of the unit is the thermopile. Unscrew this with a spanner and lower it out of the mounting. 3. The thermocouple is at the rear on the other side. This can also be removed by unscrewing with a spanner. 4. The whole bracket with the pilot can then be removed by unbolting it from the front of the frypan where it is attached or by removing two screws on the side which join the pilot assembly to the plate mounted to the frypan. THERMOSTATS The control thermostat is a Robertshaw RX model with a centre stem which can be adjusted to temperatures between 50 C and 190 C. The safety thermostat is a... with a maximum setting of 230 C. This is connected to the thermocouple circuit and it designed to cut off the gas supply if the control thermostat fails. Before the fryer will operate again the control thermostat will have to be reset by pressing the red button which is visible below the operating REMOVING THE CONTROL THERMOSTAT 1. Remove the dial knob by pulling it outward. 2. Remove the two mounting screws on either side of the spindle and pull the thermostat out from behind. 3. Follow the thermostat phial lead to the stuffing box in the fry pan. 4. Undo the compression nut holding the thermostat in place and withdraw it. 5. Undo the electrical connections from the multifunction gas controller.

11 11 SYSTEM RESISTANCE CHECK REMOVING THE SAFETY THERMOSTAT 8 With the thermostat contacts closed check the resistance between the TH and TH/TP terminals. If the resistance is above 80m/ohms then the resistance can be reduce in the following ways. 1. Clean and tighten thermostat contacts. 2. Shorten wires or use a heavier gauge wiring. 3. Sweep the thermostat control knob back and forth to clean the rheostat contacts. PILOT DROPOUT CHECK Disconnect the electrical leads from the back of the safety thermostat. Follow the phial lead to the stuffing box in the frytank and undo the compression nut to withdraw the safety thermometer. Unscrew the nut around the reset button and pull it out from behind. CALIBRATING THE CONTROL THERMOSTAT Calibration of the control thermostat can only take place when the fryer is fully operational. 1. Ensure that the oil tank is above the minimum level before lighting they fryer. 2. Light the fryer according to the user instructions and set the burner to 180 C (356 F). 3. Remove the control knob by pulling it out without changing its position. 4. Allow the fryer to heat up through three cycles of the burners turning on and off. 5. When the burners light up again wait until the oil has reached its peak temperature again and measure the temperature of the oil 25mm below the surface in the middle of the pan using a high quality thermometer or pyrometer probe. 6. The temperature reading should be between 171 C-185 C (340 F-365 F). 7. To adjust the thermostat control, steady the spindle and use a very small flat screwdriver to turn the adjustment screw in the centre. Turn the screw clockwise to decrease the temperature and counterclockwise to increase it. A quarter of a turn is equal to about a 27 C change in the setting. 8. Allow the unit to operate for a while until the temperature has settled and then check with oil with a thermostat or pyrometer again.

12 9 REMOVAL OF THE MULTIFUNCTION GAS CONTROL 1. Unscrew the thermocouple fitting and pull it clear. 2. Unscrew the thermopile connections and pull them clear. 3. Unscrew the pilot burner connection and pull it clear. 4. Undo the main gas outlet pipe and then the inlet pipe while supporting the gas controller. 5. Reverse these steps to replace. CLEANING THE MAIN VALVE 1. The multifunction gas control must first be removed. 2. Remove the bottom plate using a security torx driver. 3. Gently lift the diaphragm all the way around the edge and then remove the diaphragm, spring and valve assembly. 4. Clean the valve face using a clean, lint-free cloth. 5. Replace the valve assembly ensuring that the diaphragm sits correctly in the casting cut-out. 6. Ensure that the spring is located correctly on the rubber projections in the centre of the diaphragm. 7. Replace the bottom cover so that the spring sits in the centre recess and replace the torx screws securely. 8. When the control has been replaced and the gas turned on again, check the bottom cover for gas leaks using a soapy solution. LUBRICATING THE GAS COCK PLUG 1. Isolate the incoming gas supply and remove all the fittings on the top part of the control such as the pilot gas supply, thermocouple and electrical connections. 2. Turn the control knob to the ON position. 3. Remove the upper part of the top casing housing the actuator by undoing the four screws at the corners and gently lifting it up with the gasket. 4. Undo the other screws holding down the top cover and lift it up, taking care not to damage the body gasket when the cock spring comes out. 5. Take note of the keyway position of the top plug before removing the cock from the body. You may have to rotate it slightly when taking it out. 6. Clean the old grease from the plug but do not clean the cavity Lubricate sparingly with suitable grease for an aluminium gas cock. 8. Replace the gas cock ensuring that the keyway is in the same position as it was before removal. 9. Replace the cock spring and gasket. The gasket holes should be positioned over the raised bosses around the screw holes. 10. Replace the top cover making sure that the cock spring enters the hub of the dial shaft and that the rubber face of the safety control valve clears the edge of the body casting. 11. Hold the cover in place while replacing the screws. 12. Replace the actuator and its gasket and fix securely. 13. Replace all necessary connections such as the pilot gas supply and electrical connections. 14. After the gas supply has been turned on again check for gas leaks using a soapy solution. TROUBLESHOOTING THE MILLIVOLT ELECTRICAL SYSTEM Before testing the electrical system, check that the system is correctly wired and that all connections are clean and secure so that there is no unnecessary resistance. The pilot jet should be cleaned and the pilot flame adjusted for maximum performance. For testing this circuit you will need an accurate meter with a range of mV. SYSTEM CHECK With the thermostat contacts closed, check the reading between the TP and TH terminals. If the reading is above 100mV and the automatic valve does not respond, replace the automatic valve. If the reading is below 100mV the perform the following checks: THERMOPILE OUTPUT CHECK With the thermopile contacts in the open position check the reading between the TP and TH/TP terminals. First adjust the pilot flame to its minimum. If no reading is obtainable then adjust the pilot flame to its maximum and take the reading. If the reading is less than 325mV then replace the thermopile.

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