Mono AZTEC Operating instructions

FG059 Aztec plc RevB18 12-12-18
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OPERATING AND MAINTENANCE MANUAL
AZTEC
DOUGHNUT FRYER
(PLC / MK3)
Enter Serial No. here.____________________________
In the event of an enquiry please quote this serial number.
www.monoequip.com
FILE 7

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SAFETY SYMBOLS
The following safety symbols are used throughout this product documentation and
manual (available at www.monoequip.com).
Before using your new equipment, read the instruction manual carefully and pay special
attention to information marked with the following symbols.
IMPORTANT NOTES
Special attention should be given to the bottom of the top tank so
that a layer of sediment is not allowed to build up. As the
temperature sensors will not be able to function correctly, a fire could
result.
Do not mix different makes or types of frying oil as a reaction
can result in a thick flour-like sediment forming in the lower tank
which can block the filtering system.
DO NOT POUR USED OIL
DOWN DRAINS OR SINKS.
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
will result in electric shock.
Indicates a hazardous situation which, if not avoided,
will result in minor or moderate injury.
WARNING
WARNING
CAUTION

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Safety during emptying and cleaning of fryers
Health and Safety
Executiv
HSE information sheet Catering Information Sheet No 17
Introduction
This information sheet was produced by the Hospitality and Catering Industry Liaison Forum, which
has members from trade and professional associations, unions and enforcement authorities.
Members’ associations are free to reproduce and distribute this guidance to catering establishments.
The guidance is issued by the Health and Safety Executive.
This sheet provides advice to employers in the catering industry on safe emptying and cleaning of
fryers. It gives guidance on manual emptying and cleaning and guidance on fryers with automated or
semi-automated filtering (using enclosed portable filtering units).
Automated and semi-automated filtering processes avoid operators coming into contact with hot oil,
significantly reducing the risks. This enables filtering to take place safely even while the oil is at normal
cooking temperature. Most automated or semiautomated systems require an oil temperature of at
least 100 °C for the filtering process to work effectively.
You should only carry out manual emptying and filtering of fryers when the oil has been cooled
to 40 °C or below.
Key messages
■■Burns from hot oil can be very serious.
■■Oil takes only 6–7 minutes to heat up but can take 6–7 hours to cool down again.
What the law says
The Health and Safety at Work etc Act 1974 (the HSW Act) places a duty on employers to ensure, so
far as reasonably practicable, the health, safety and welfare of their employees. This duty extends,
amongst other things, to providing and maintaining systems of work which are, so far as reasonably
practicable, safe and without risks to health. The HSW Act also places a duty on employees to
take reasonable care of their own and others’ health and safety.
Whichever type of fryer is used, you must:
■■ensure the fryer is well maintained and any attachments used are suitable for their purposes,
as recommended by the manufacturer – a procedure for reporting faults will help you comply with this duty;
■■train staff in a safe system of work for emptying and cleaning;
■■provide staff with suitable protective equipment where required by the risk assessment, eg eye
protection, heat-resistant gloves, aprons.
When to empty and clean
■■Many catering establishments are closed overnight. For fire safety and economy switch off fat fryers
when unattended. Carry out oil filtering and cleaning as a first task of the day rather than as part of the
closing-down procedure.
Hazards
The hazards in emptying and cleaning fryers include:
■■fire;
■■burns from hot oil;
■■contact with hot surfaces;
■■fumes from boiling cleaning chemicals;
■■boiling chemicals overflowing;
■■eye injuries from splashes;
■■slips from oil spillage;
■■strains and sprains from lifting and moving containers of oil. If the catering service runs for 24 hours
and the appliance is required continuously, there are two safe options:
Health and Safety Executive
CATERING INFORMATION SHEET No. 17

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Page 2 of 4
■■Use more than one fryer and clean them in rotation.
■■Use an automated filtering system or a semiautomated portable filtering unit that removes the
hot oil directly from the fryer, filters the oil and holds it safely.
Automated and semi-automated filtering
Automated filtering systems
An automated system consists of an inbuilt oil filtration system. The oil is drained into an enclosed reservoir
and an electric pump circulates it through a filter system and internal pipework back into the fryer.
Since this process is enclosed within the equipment, the operator does not come into contact with hot oil,
greatly reducing any risk.
Portable oil filtering units (semi-automated)
These units are not part of the fryer, but sit alongside it. The operator attaches an extension pipe to the
fryer and the hot oil is drained into an enclosed container within the portable unit. The oil is then filtered
and returned to the fryer.
If you have a fryer with automated oil draining system or a portable oil filtering unit, refer to the
manufacturer’s guidelines for draining/filtering temperatures and safe operational requirements.
These, together with your own risk assessment, will determine the need for suitable protective equipment.
If there is still a risk from contact with hot surfaces or oil splashing, you may need to provide staff with eye
protection, a protective apron and/or heat-resistant gloves/gauntlets.
Manual oil filtering
This involves the operator draining the oil from the fryer through a filter into a suitable metal-holding or
heat-resistant hard, plastic container and manually lifting it back into the fryer (fryer oil is often supplied in
hard, plastic, rigid containers). Serious accidents have occurred where oil that has not sufficiently cooled
has been drained back into an empty plastic container and the base of the container has given way.
To drain oil safely and in the correct sequence, follow these guidelines:
■■Turn off the appliance and the power supply at the wall socket for electric appliances, and the on/off
control for gas appliances.
■■Allow the oil to cool, ideally for at least six hours, and check the temperature using a suitable probe
thermometer before draining. Do not drain if the temperature is above 40 °C.
■■Follow the manufacturer’s instructions and use the correct equipment (eg a detachable spout for the
type of fryer you are emptying), making sure to bring any equipment you need to the fryer before you start.
■■Depending on the type of fryer, drain the oil by drain valve, removable spout, lifting container or by
tilting.
■■If the oil is too cold to drain easily, reheat it briefly and agitate with the fryer basket for no more than
one minute. Switch the appliance off and check the temperature again before emptying.
■■Using a filter, run the oil into a suitable metal holding or heat-resistant hard, plastic container.
These containers will generally need carrying handles and a cover or lid. Before moving, make sure that
the lid or cover is secure.
■■Make sure the container is empty and big enough to take the volume of oil being drained at any time.
■■When you are draining large volumes of oil it is safer to drain off in smaller amounts. This avoids
overfilling the container and will reduce the chance of spillages when you move it. Smaller amounts
will also be easier to carry.
■■Place the container in a safe place where it cannot be contaminated with chemicals, water or foreign
bodies. Place the container on top of a drip tray to avoid any floor contamination.
■■Do not dispose of waste oil down the drain – disposal must comply with environmental legislation.
■■Clean up any spillages immediately.
■■Make sure floor areas around equipment are completely clean and dry to avoid slip risks (see also
Preventing slips and trips in kitchens and food service).
Other precautions
Make sure the design of the drain-off tap prevents it being turned on accidentally:
Health and Safety
Executive
Page 3 of 4
■■Mark clearly on it that the tap should not be touched.
■■Place warning signs near the tap.
■■If possible, remove the tap handle when the fryer is switched on.

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Cleaning procedure
This section applies to all types of fryers.
■■Turn off the appliance, and the power supply at the wall socket for electric appliances and the on/
off control for gas appliances.
■■Wear suitable protective equipment, including eye protection (if appropriate).
■■Check that other activities will not be put at risk by the cleaning activity.
■■Check that the oil has been thoroughly drained and that there are no spillages that may cause slipping.
■■Remove loose debris from the internal surfaces.
■■Thoroughly wash all internal and external surfaces with suitable cleaning chemicals and check for any
leaks.
■■For stubborn residues, fill the fryer with your recommended cleaning agents and leave or simmer
according to instructions.
■■Do not leave the fryer unattended or allow it to boil as this may cause it to cascade liquid onto the floor,
causing additional scalding and slipping hazards.
■■Drain the appliance and rinse thoroughly with plenty of water.
■■Dry all internal surfaces and make sure there is no water left in the fryer.
■■Check the drain valve is closed and working properly, then refill and switch on as required.
■■When refilling the fryer with oil, the oil container may be too large or heavy for one member of staff.
Where possible, use smaller containers.
■■Do not overfill the fryer. Follow the manufacturer’s guidelines.
■■Clean up any spillages immediately.
■■Make sure floor areas around the equipment are completely clean and dry to avoid slip risks.
Training
This section applies to all types of fryers.
■■Make sure only staff trained in the safe use of the cleaning chemicals and cleaning procedures for the
fryer do this task.
■■Train staff in reporting procedures if they find the equipment is faulty or if they have experienced any
practical difficulties with cleaning the fryer in their specific work environment.
■■Make staff aware of the reason for using suitable protective equipment, ie gloves, eye protection.
■■Complete risk assessments for hazardous chemicals and make staff aware of the correct
procedures for using cleaning chemicals.
■■Make safety data sheets available to staff.
■■A short, written procedure can act as a reminder to staff for both draining and cleaning operations.
Further reading
Preventing slips and trips in kitchens and food service
Catering Information Sheet CASI6(rev2) HSE 2012
www.hse.gov.uk/pubns/cais6.htm
Safe use of cleaning substances in the hospitality industry Catering Information Sheet CAIS22(rev2)
www.hse.gov.uk/pubns/cais22.htm
HSE has produced a suite of Catering Information Sheets and other guidance for the catering and
hospitality industry. These are available on the HSE website at www.hse.gov.uk/catering/index.htm
There is also helpful advice in Health and safety made simple: The basics for your business
www.hse.gov.uk/simple-health-safety

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CONTENTS
Section - 1.0 Introduction
Section - 2.0 Dimensions
Section - 3.0 Specifications
Section - 4.0 Safety
Section - 5.0 Installation
Section - 6.0 Cleaning Instructions
Section - 7.0 Operating conditions/instructions
Section - 8.0 Maintenance
Section - 9.0 Fault finding
Section - 10.0 Spares and service
Suggested Spares List
ENGINEERS INFORMATION
Section - 11.0 Electrical Information
Setting timer and temperature
Wiring diagrams
IMPORTANT NOTE
Special attention should be given to the bottom of the top tank so
that a layer of sediment is not allowed to build up. If the sediment
does build up a fire could result, as the temperature sensors will not
be able to function correctly.
Do not mix different makes or types of frying oil as a reaction
can result in a thick flour-like sediment forming in the lower tank
which can block the filtering system.

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1.0 INTRODUCTION
The MONO fryer makes the doughnuts, you make the profits - it’s as easy as that. Just
set the controls, load a tray and the MONO Aztec takes over: Up to 900 doughnuts can
be produced every hour with the minimum of supervision.
The MONO Fryer saves on cooking oil and electricity, as only the oil in the vicinity of the
frying basket is heated to full working temperature, and is thermostatically controlled.
Oil top up and doughnut turning are fully automatic.
2.0 DIMENSIONS
Height: Frying unit in raised position 1400mm (55”)
Width: Left hand fitted draining board 1905mm (75”)
Depth: 970mm (38”)
3.0 SPECIFICATIONS
Power: 12.5 kW; three phase & Neutral
Output: Float frying - up to 900 doughnuts per hour.
Capacity: 45 doughnuts per tray.
Frying tank
capacity: 80 Ltrs (21 gallons).
Top up tank
To level mark: 20 Ltrs (5.25 gallons)
Frying trays: MONO 762mm x 457mm (30”x18”)
Weight: 160kg (353lb).
Noise level: Less than 85dB.
100 Ltrs Total
The supply to this machine must be protected by a
30mA RCD

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4.0 SAFETY
EXCEPT FOR OIL FILTERING ALL CLEANING AND MAINTENANCE OPERATIONS
MUST BE MADE WITH FRYER DISCONNECTED FROM THE POWER SUPPLY
1Never use the fryer in a faulty condition and always report any damage.
2No-one under the age of 16 may operate this machine.
3No-one under the age of 18 may clean this machine under any circumstances.
4Only trained personnel may remove any part from this fryer that requires a tool
to do so.
5Always ensure hands are dry before touching any electrical appliance (including
cable, switch and plug).
6All operatives must be fully trained.
7People undergoing training on the machine must be under direct supervision.
8Do not operate the machine with any panels removed.
9All guards must be fixed in place with bolts or screws unless protected by a
safety switch.
10 No loose clothing or jewellery to be worn while operating the fryer.
11 Switch off power at the mains isolator when fryer is not in use and before carrying
out any cleaning or maintenance.
12 The Bakery Manager or the Bakery Supervisor must carry out daily safety
checks on the fryer.
13 Please read the H.S.E. information sheet contained in this manual.(see pages 4,5)
Special attention should be given to the bottom of the top
tank so that a layer of sediment is not allowed to build up.
If the sediment does build up a fire could result as the
temperature sensors will not be able to function correctly.

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5.0 INSTALLATION
1It is recommended that the Aztec Doughnut Fryer should be sited away from
any main thoroughfare and that the surrounding floor area should be
covered with an appropriate brand of non-slip surfacing.
2VENTILATION should be provided with an extraction canopy to ensure that
convected heat and cooking smells are removed from the building. The canopy
should extend a minimum of 300mm (12”) beyond each edge of the fryer and have
its lowest point between 1980mm (70”) and 2740mm (108”) above the floor.
The extraction canopy should be fitted with a cleanable grease trap.
3Fittings are provided for the attachment of the draining board.
4ELECTRICAL CONNECTION
The fryer should be connected to a 25 Amp 3 phase plus neutral isolator at 25
Amp with a BS 88 fuse.
Aztec doughnut fryers are dispatched with the carrier (1) in the mid-way
position to avoid damage during the following check procedure:
5When turning the main power switch (4) on, watch if carrier (1) moves up or down.
Turn power off immediately before the carrier reaches top or bottom positions.
If carrier moves UP, this is CORRECT.
If carrier moves DOWN, this is NOT CORRECT.
Swap round any two of the phase carrying wires at main isolator feeding the fryer.
(5)
(5)
(6)
(4)
(1)
CORRECT
NOT
CORRECT
CARRIER START
UP DIRECTION
The supply to this machine must be protected by a
3
0mA RCD

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6Turn main isolator switch (4) to ‘OFF’(horizontal position).
7Remove two screws (5).
8Remove cover (6).
9Switch element MCB’s (in control box) to on position.
10 Replace cover (6) and screws (5)
11 Switch on main control switch (4)
ISOLATION
TO STOP THE DOUGHNUT FRYER
IN AN EMERGENCY,
SWITCH OFF THE MAINS WALL ISOLATOR.
ELEMENT MCB’s

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6.0 CLEANING INSTRUCTIONS
WARNING:
ISOLATE FROM MAINS SUPPLY BEFORE CLEANING AND ALLOW TO COOL.
HOT OIL IS DANGEROUS
DAILY
Wipe down exterior bodywork with a damp cloth and cleaning fluid.
•TO CLEAN OIL FILTER BAG
ALLOW OIL TO COOL BEFORE ATTEMPTING TO REMOVE FILTER
1Open front doors.
2Pull lower tank towards you.
3Unclip poppers around top edge and remove filter.
4 Only use hot water to clean filter. Do not use soap or detergent. Do not
clean in a dishwasher.
5Ensure filter is dry and replace on to filter holding bars, ensuring all poppers are
done up.
6Push lower tank back under machine. Close doors.

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•REMOVAL OF TURNOVER DEVICE AND SEPARATOR
UNIT FOR CLEANING
Before proceeding with the following,
the fryer must be allowed to cool and oil drained
1Lift turnover device off rear bars as shown
in photo. (CAUTION UNIT IS HEAVY).
2Turn separator unit adjuster to position 1.
3Lift separator unit carefully and remove from
tank. (CAUTION UNIT IS HEAVY).
4 Lift the Elements carefully & rest on the
back of the Fryer
5 Remove any sediment from the bottom
Of the tank & discard.
6 Wipe the tank clean & replace components
in reverse order
NOTE
Special attention should be given to the bottom of the top tank
so that a layer of sediment is not allowed to build up. If the sediment
does build up, a fire could result as the temperature sensors will not be
able to function correctly.
POSITION 1
1
2
4
6
3
5

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7.0 OPERATING INSTRUCTIONS
•
OIL LEVEL
CONFIRMATION
BUTTON.
ONLY PRESS WHEN
BUZZER IS HEARD
AND LIGHT FLASHES
AND ONLY IF OIL IS
IN
THE
TOP TANK.
TURN OFF.
STARTS THE FILTER
OPERATION AND
THEN TURNS OFF
TURN ON.
STARTS HEAT UP
AFTER OIL
CONFIRMATION
BUTTON PRESSED.
OPERA
TION
BUTTON.
STARTS THE FRY
AND TURNOVER
OPERATION
LIGHTS WHEN POWER
SUPPLY CONNECTED
LIGHTS WHEN
ELEMENTS ARE
HEATING
CONTROL PANEL
IF A TRAY IS NOT PL
ACED
IN THE CORRECT
POSITION, AS SHOWN
DURING TRAINING, THE
CARRIER MAY JAM IN
POSITION.
IF THIS HAPPENS PRESS
CARRIER RETURN SWITCH
ONCE AND THE CARRIER
WILL RETURN TO THE
START POSITION.
4
1
2
3
6

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•FILLING WITH FRYING OIL.
•Fill tank with cooking oil until oil is flowing into the bottom tank via the
overflow slot at the back of the main tank. Allow flow to stop then pull out
lower tank.
•Fill bottom tank with oil to level shown on the back wall of the tank
Do not overfill or spillage will occur during filtering.
OIL LEVEL
LINE
BOTTOM TANK
Do not mix different makes or types of frying oil
as a reaction can result
in a thick
flour-like sediment forming in the lower tank which can block the filtering system.

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•HEATING UP
1 Ensure top control panel switch is in “ON / HEATERS” position
2Turn on main power supply.
***Buzzer sounds***
3If there is oil in top tank, press “OIL LEVEL CONFIRMATION “ button.
Oil will now heat to cooking temperature.
NOTE
Until the oil is heated to cooking temperature the up and down operation will not work.
DO NOT TURN POWER OFF UNTIL FULL FILTER CYCLE HAS FINISHED.
DO NOT LEAVE MACHINE WITH ALL THE OIL IN THE BOTTOM TANK, (ALWAYS
LET OIL PUMP BACK TO TOP TANK BEFORE LEAVING MACHINE.)
CAUTION!!
ELEMENT HEATING WILL STOP WHILE PUMP IS IN OPERATION. TO PROTECT THE
ELEMENTS, ENSURE OIL IS IN TOP TANK AT ALL OTHER TIMES. I.E WHEN TURNING
MAIN POWER ON.
DO NOT PRESS UNLESS THERE IS THE CORRECT AMOUNT OF OIL IN THE TOP TANK
1
2

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•ADJUSTMENT OF TURNOVER DEVICE
Depending on the size or shape of the doughnut being fried, the separator unit must be
adjusted.
1Turn Knob (A) on right hand side of tank, clockwise or anticlockwise.
2Read off scale (B) on left until required position is found.
3The positions required will have to be determined and recorded for future
reference.
4 Generally position 1is for large products and
position 4is for very small or finger doughnuts.
(B
(B(B
(B
)
))
)
(A
(A(A
(A)
))
)

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•OPERATION
1Slide tray into cradle.
Ensure that the tray is pushed up against the cradle end stops.
( This must be correct or the machine will jam).
2Press black button to start frying sequence.
Cradle will lower tray into the first position and wait before lowering again
and turning the doughnuts over. After the preset time the cradle will lift to the top
position allowing the doughnuts to drain.
3Slide the tray onto the drainer and insert a fresh tray into the cradle.
4 Check at regular intervals that the oil level in the lower tank reaches the
“Max Oil Level” line engraved on the inside back left corner.
DO NOT FILL ABOVE THIS LINE or oil will overflow during filtering.
NOTE
IF A TRAY IS NOT PLACED IN THE CORRECT POSITION, AS SHOWN
DURING TRAINING, THE CARRIER MAY JAM IN POSITION. IF THIS
HAPPENS, A CARRIER RETURN SWITCH CAN BE FOUND AT THE
BOTTOM OF THE CONTROL PANEL. PUSH ONCE AND THE CARRIER WILL
RETURN TO THE START POSITION.
3
6

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•FILTERING WHEN TURNING OFF
1Ensure lower tank is pushed fully back on runners.
2Turn top switch to “OFF FILTER” position.
3After 30 seconds the drain valve will open and the return pump will be heard
operating.
4After about 9 minutes the valve will close and the top tank will start to fill up again.
When the pump stops the main power can be switched off.
DO NOT…….
DO NOT TURN POWER OFF WHILST PUMP IS OPERATING
4