Lincat Opus 800 Series Manual

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Opus 800 Vortech Gas Fryer
OG8115/OP
User, Installation and Servicing Instructions

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Dear Customer,
Thank you for purchasing this Lincat product.
This is just one of over 450 different items of catering equipment available
which is constantly being extended and improved. Details are available from
your local distributor or direct from us.
Used for the purposes for which it is intended, and with careful maintenance
as outlined in this User Guide, your Lincat product will give you years of
trouble free service.
IMPORTANT INFORMATION
Please read all of the safety and operating instructions carefully before using this
product. Please pay particular attention to all sections of this User Guide that carry
warning symbols and notices.
WARNING!
This is a Warning symbol. This symbol is used throughout the user guide whenever
there is a risk of personal injury. Ensure that these warnings are read and understood
at all times.
CAUTION!
This is a Caution symbol. This symbol is used throughout the user guide whenever there is a
risk of damaging your Lincat product. Ensure that these warnings are read and understood at
all times.
NOTE:
This is a Note symbol. This symbol is used throughout the instructions to provide
additional information, hints and tips.
EQUIPOTENTIALITY
This equipment is provided with an equipotential bonding terminal to allow earth cross-
bonding with other equipment.

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CONTENTS
Contents Page
Customer Information………………………………………………………. 2
Warnings and Precautions………………………………………………… 3-4
Technical Data……………………………………………………………….. 4
Check List of Enclosures………………………………………………….. 5
Component Identification…………………………………………………… 5
Installation…………………………………………………….……………… 6
Commissioning……………………………………………………………… 7-8
Servicing ……………………………………………………………………… 9
Component Replacement ………………………………………….……… 9-12
Spare Parts List……………………………………………………………… 12
Fault Finding…………………………………………………………………. 13
User Instructions……………………………………………………………. 14-15
Service information………………………………………………………….. 16
Guarantee………………………………………………………….………….. 16
WARNINGS AND PRECAUTIONS
Please read the following carefully before commencing work on this unit.
WARNINGS AND PRECAUTIONS
This appliance must be installed by a competent installation engineer in accordance with
the installation instructions, and should conform to the following requirements:
Gas Safety (Installation & Use ) Regulations
BS 5440: Flues, Air Supply for gas appliances of input not exceeding 70kW (1st, 2nd and 3rd
family gases)
Institution of Gas Engineers publications: IGE/UP/1, IGE/UP/2 and IGE/UP/4
BS 6173: Code of Practice for Installation of Gas Catering Appliances
Local and National Building Regulations
Fire Precautions Act
Health & Safety At Work etc Act
It is mandatory that all appliances are installed, commissioned and serviced by a
qualified and competent person as defined by the regulations in force in the country of
installation. Failure to comply will invalidate the warranty.
This appliance is for professional use only and must only be used by qualified people.
All equipment must be earthed to prevent shock.
Disconnect the unit from the electricity supply before servicing or undertaking any electrical
maintenance.
Parts, which have been protected by the manufacturer or his agent, must not be adjusted by
the installer or user.

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If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or
similarly qualified persons in order to avoid a hazard.
Parts of this unit may become hot in normal use; therefore suitable precautions must be taken
to avoid accidental contact.
Do not move this appliance when the tank contains oil.
Hot oil can cause severe burns. Avoid direct physical contact.
Always drain food before frying.
Never put water into the oil, as this will cause splashing and possible overflow of the tank.
Never put anything other than food into the oil.
Never leave the unit unsupervised whilst frying.
If the unit should begin to smoke, switch off immediately.
In the event of a fire occurring, water should not be used to extinguish it. It is advisable to
install a suitable fire extinguisher and have a fire blanket within reach of the fryer.
Do not use old oil, it will have a reduced flash point and be more prone to surge boiling.
Do not overheat the oil.
Do not replenish the oil whilst the fryer is hot.
Do not overfill the tank with oil; maintain the oil level above the minimum mark.
Do not obstruct or block the appliance flue
Do not connect directly to any flue, ducting or mechanical extraction system
Installation should allow for a sufficient flow of fresh air for combustion air supply
Installation must include sufficient ventilation to prevent the occurrence of unacceptable
concentrations of substances harmful to health in the room in which they are installed
It is recommended that this appliance is sited under an extraction canopy for the removal of
combustion products.
Do not use flammable solvents and cleaning aids.
TECHNICAL DATA
Description
Single Tank Gas Fryer
Model number
OG8115/OP
Overall height (mm)
1070
Width (mm)
400
Depth excluding handles (mm)
800
Weight (Kg)
92
Oil capacity (Litres)
16
Maximum frying weight
3.0 kg
Gas inlet connection
½” Rp
Gas pressure –Natural (G20) I2H
20 mBar
Gas pressure –Propane (G31) I3P
37 - 50 mBar
Gas pressure –Butane (G30) I3B/P
30 - 50 mBar
Heat input (Gross)
22 kW (75,064 Btu’s)
Gas rate –Natural (G20) I2H
2.10 m3h-1
Gas rate –Propane (G31) I3P
1.57 kg h-1
Gas rate –Butane (G30) I3B/P
1.60 kg h-1
Combustion –Natural (G20) I2H
CO2–9.5%±0.2 CO ˂20 PPM
Combustion –Propane (G31) I3P
CO2–10.5%±0.2 CO ˂20 PPM
Combustion –Butane (G30) I3B/P
CO2–11.0%±0.2 CO ˂20 PPM
Propane Orifice
Ø5.1 mm
Butane Orifice
Ø4.7 mm
Power rating (watts)
250

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NOTE
Please ensure the following items are included with this piece of equipment:
Model
Filtration
Tick
Wire basket
1
Batter plate
1
Drain bucket
1
Oil return lance
1
Oil return hose
1
Filter bag/ Filter bag frame
1
Stainless drain basket
1
User/Installation instructions
1
Guarantee card
1
SERIAL NUMBER
Each appliance manufactured at Lincat has a unique identifying number found in the top right hand corner of
the data plate attached at the rear of the appliance. Please record that number in the space provided should it be
required for future reference.
Serial Number
MARK OF CONFIDENCE
Every single product that leaves our factory bears a serial plate showing the assembler’s initials. It’s a
mark of confidence we have in our people and our manufacturing process.
CHECK LIST OF ENCLOSURES
A
Knurled fastener
B
Power On
C
Burner On
D
Thermostat knob
E
Operating mode
F
Burner reset
G
Limit thermostat reset
H
Oil pump connection
I
Oil bucket
J
Drain valve handle
K
Drain valve lock
L
Coupling
M
Oil return lance

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PREPARATION
Remove all packaging materials and protective coatings prior to installation.
VENTILATION
The area in which this equipment is to be installed should have sufficient fixed ventilation to comply
with local legislation requirements. It is recommended that a room or internal space be provided with
a minimum free area of 4.5cm2per kW (3,400Btu/hr) of total heat input.
SITING
The appliance must be installed in accordance with the appropriate regulations listed prior.
It is recommended that this appliance is sited under an extraction canopy for the removal of
combustion products.
The appliance should be installed on a level surface, in a suitable position that is well lit and draught
free, and positioned to minimise the possibility of accidental touching.
A clear space of at least 100mm must be left to the rear of the appliance to allow for servicing with a
clear space of 600mm to the front to allow for safe operation.
A minimum space of 100mm must be left between any side of the unit and any combustible surfaces
or walls.
Any partitions, walls or kitchen furniture less than 100mm from the appliance must be of non-
combustible materials. Should a flexible hose be used the unit must be secured to the wall by
the use of a chain.
ELECTRICAL SUPPLY AND CONNECTION
If the supply cable is damaged it should be replaced by Lincat Ltd or other suitably qualified persons,
in order to avoid a hazard.
For safety regulations the plug or means of disconnection must always be accessible.
This unit must be earthed.
This unit is supplied with a 13 amp plug. If replacing the plug, connect the terminals as follows:
Green and yellow wire
Earth
E
Blue wire
Neutral
N
Brown wire
Live
L
GAS SUPPLY AND CONNECTION
Check that the gas supply corresponds to that specified on the data plate.
Connection is at the rear of the unit via a ½” Rp thread. The gas supply tubing or hose shall comply
with the national requirements in force and shall be periodically examined and replaced as necessary.
An isolating cock should be fitted into the supply line close to the unit for emergency shutdown or
servicing purposes.
If the supply pressure exceeds 37mbar for 3rd family gases then an external regulator
must be fitted at the appliance inlet.
INSTALLATION

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Never operate the unit without oil in the tank
OPERATIONAL CHECK
Although all Lincat fryers are functionally checked during manufacture, commissioning
must include a functional check of all controls.
PREPARATION
Having sited the unit, with particular attention paid to ventilation and proximity to combustible
materials as detailed previously, the unit is ready for commissioning.
Connect gas supply and check for gas soundness.
Connect to the electrical supply as previously outlined.
Ensure that the oil drain tap is closed.
Remove the filter bag/holder and the stainless basket from the oil drain tank.
Clean the fryer tank thoroughly with a warm mild detergent solution.
Rinse the tanks, drain pipes and taps, and then dry thoroughly.
Run a small quantity of oil across the bottom of the tank. Open the drain tap and drain any
residual water into the oil drain tank. Coat the base of the tank with a layer of oil.
Close the drain taps.
Empty oil drain tank, dry thoroughly.
Place the stainless drain basket and filter bag into the drain tank.
Re-fit oil drain tank back into the base of the fryer.
Fill the tank with oil to the lower level mark.
LIGHTING SEQUENCE
Please ensure that the gas isolation valve for the appliance is turned to the open position
before attempting to light this unit.
With the control knob in the off position and the ‘Filter/fryer mode’ toggle switch in fryer
mode, switch the unit on at the isolator. The green neon will light.
Turn the thermostat control knob clockwise to the required temperature.
The adjacent amber neon will light, indicating that the burner is running.
Use a suitable device to check the temperature of the oil at a position 25mm below the surface
of the oil, at the geometric centre of the tank.
Using a calibrated combustion analyser, measure the products of combustion at the appliance
flue outlet.
COMMISSIONING

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Natural gas CO2–9.5%±0.1 CO ˂20 PPM
Propane gas CO2–10.5%±0.1 CO ˂20 PPM
Butane gas CO2–11.0%±0.1 CO ˂20 PPM
If required, adjustment is made via the venturi
throttle screw after removing the access panel.
Anticlockwise increases the gas making the
mixture richer and increasing the CO2
percentage.
Clockwise decreases the gas making the mixture
leaner and decreasing the CO2percentage.
FILTER MODE
HOT OIL –Wear protective clothing, gloves and safety glasses.
When filtering oil during normal service, set the control knob to the ‘off’ position, wait
for at least 5 minutes before draining to allow the unit to cool.
Isolate the unit from the gas supply.
Set the thermostat control knob to the off position.
Ensure the oil suction pipe is secure within the drain tank and that the drain tank is pushed
fully onto the oil inlet pipe.
Ensure the filter bag is within the filter bag frame and correctly aligned in the drain tank.
Ensure that the stainless drain basket is sitting in the filter bag.
Open the drain valve and allow the oil to drain. Close the drain valve.
Connect the oil return lance to the quick release coupling.
To operate the pump set the ‘Filter/fryer mode’ toggle switch in filter mode.
The pump will operate for a predetermined time before stopping.
It is normal for a small amount of oil to remain in the bottom of the drain tank.
To stop the pump set the ‘Filter/Fryer mode’ toggle switch to Fryer mode.
The green neon will light.
This manual together with the user instructions must be kept in a safe and accessible
place for future reference.
Ensure that the person responsible understands how to safely operate, clean and shut down
this appliance and is made aware of the position of the gas isolating cock, the electrical supply
isolation switch in the event of an emergency, the reset for the limit stat, the burner and the
filtration pump.

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We recommend that all servicing, other than routine cleaning, be carried out by our
authorised service agents.
ROUTINE SERVICE
1. Carry out a general check of the installation paying particular attention to the following:-
Has the unit been installed using the correct hose?
Does the unit have a safety chain?
Does the equipment have a separate isolation valve?
Is it connected to the supply via a suitable isolating switch?
2. Carry out a gas soundness check.
3. Check that the gas supply is adequate without excessive pressure drop. A test nipple is located on
the gas inlet standpipe.
4. Ensure that the flue is clear and check the combustion with a calibrated instrument.
5. Check the operation of the high temperature limit thermostats. The reset button is located on the
front panel, see diagram.
6. Check the pump operation, the quick release coupling and plug connection and flexible hose
condition and that there is no evidence of leaks on the filtration circuit.
Disconnect from both the gas and electrical supply before proceeding with any of the
following instructions.
Use only genuine Lincat spares.
TEMPERATURE CONTROL
Remove the control knob.
Undo the control panel retaining screws.
Remove the screws that retain the temperature control/switch assembly to the control panel.
Disconnect the cable from the rotary switch.
Pull the temperature control from the switch to separate then undo the lock nut.
Reassemble in reverse order.
SERVICING
COMPONENT REPLACEMENT

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SAFETY THERMOSTAT.
Drain the fryer tank.
Undo the control panel (see above).
Undo the gland assembly and withdraw the capillary and bulb.
Remove the drain valve handle
Undo the four screws retaining the switch panel.
Undo the nut holding the limit stat to the switch plate. Disconnect the wiring.
Reassemble in reverse order.
FLAME SENSOR, IGNITER ELECTRODE AND LEADS
Remove the drain valve handle
Undo the four screws holding the switch panel and support under the drain valve.
Pull off the electrode cap and disconnect from the PCB (if replacing the lead) and unscrew
the electrode.
Reassemble in reverse order ensuring that the earth wire is reconnected on the ignitor
electrode and always use a new gasket. Do not over tighten the screws.
DRAIN VALVE
Remove the drain valve handle
Undo the four screws holding the switch panel and support under the drain valve.
Remove the drain valve extension assembly.
Unscrew the drain valve from the unit.
Remove the outlet stub pipe from the drain valve.
Reassemble in reverse order using standard practice for the sealing of the threads.
SYSTEM PCB
Undo the control panel (see above).
Remove the right hand side panel by unscrewing the fasteners at the rear, prising the side
panel from the rear, then sliding forward until clear of the front frame.
Identify, then remove all connections. Remove the two fasteners holding the PCB bracket.
Withdraw the PCB assembly then undo the M4 nuts to allow removal of the PCB.
Reassemble in reverse order.