ULTRAFRYER ZRT3-H Technical manual
ULTRAFRYER GAS FRYER
14 & 18” MODEL ZRT3-H with EZ DOCK FILTRATION
OPERATION INSTRUCTION
302 Spencer Lane • P.O. Box 5369 San Antonio, Texas 78201
(800) 525-8130 • (210) 731-5000 • Fax: (210) 731-5099
WARNING!!! TO PRECLUDE THE POSSIBILITY OF SPONTANEOUS COMBUSTIBLE
FILTER TUB FIRES; SLUDGE AND CRUMBS MUST BE REMOVED AND DISCARDED AND THE
FILTER TUB MUST BE THOROUGHLY CLEANED AFTER CLOSING THE STORE EACH NIGHT!!!
PREFACE
This Manual was written and published by the Technical Publications Department, Ultrafryer Systems for use
by personnel who will operate a 14” or 18” Model ZRT3-H Gas Fryer equipped with an EZ Dock Filtration
System.
TECHNICAL PUBLICATIONS DEPARTMENT
ULTRAFRYER SYSTEMS
302 SPENCER LANE
SAN ANTONIO, TX 78201
1-800-545-9189 EXT. 5007
PN 30A073 PUBLISHED JULY 2003
i
TABLE OF CONTENTS
GENERAL INFORMATION
Warranty
Safety
Description / Specications
Ultrafryer Model ZRT3-H Gas Fryer Dimensions & Operational Requirements
Operating Controls Locations
Automatic Safety Features
Rating Plate
Inlet Gas Line Sizing
Inlet Gas Requirements
PRE-INSTALLATION
General
Clearances
Standards
Air Supply & Ventilation
RECEIVING & INSTALLING THE FRYER
Unpaking
Installing
Leveling
Inlet Gas Requirement
Gas Connection
Electrical Connections
Default-To-Manual-Restart (DTMR) Control
Optional Controls
INITIAL START-UP
Cleaning
Start-up
Lighting Instructions
Sequence Of Ignition
Burner Operation Test
Shortening Installation
Start-Up and Cooking
Initial Cleaning
Cooking
OPERATING INSTRUCTIONS
General
Filtering Shortening
Leveling Shortening
Boiling Out Fryers
Closing/Shutdown Instructions
CLEANING AND MAINTENANCE
Cleaning
Maintenance
Fenwal Temperature Controller Adjustment
Electronic Thermostat Calibration
TROUBLESHOOTING & PREVENTIVE MAINTENANCE
General
Troubleshooting Chart
Preventive Maintenance
MODEL ZRT3-H RECOMMENDED SPARE PARTS
ii
iii
TABLE OF CONTENTS ...... continued
OPERATION
General
Default-To-Manual-Restart Computer Control
Ultrastat 11 Cooking Computer
Filtering Shortening
Filter Tub Assembly & Installation
Filtering & Polishing Shortening
Fryer Boil-Out, Shortening Disposal & Shortening Installation
TECHNICAL ASSISTANCE, ORDERING INFORMATION & PARTS IDENTIFICATION
Technical Assistance
Ordering Information
Parts Identication
Wiring Diagrams
GENERAL INFORMATION
1
ULTRAFRYER® LIMITED WARRANTY
Ultrafryer Systems warrants to the original purchaser of a gas or electric Ultrafryer® sold within the United States, it’s territories
and Canada, that it will be free of defects in material and workmanship for the periods listed below:
STAINLESS STEEL FRYER VAT – Stainless Steel fryer vats are warranted for (10) ten years upon the terms hereinafter
described. The (10) ten year warranty coverage applies ONLY to the Stainless Steel fryer vat and does not apply to the other
components such as controls, re boxes, gaskets, mounting hardware, or the heat shield weldment. The (10) ten year limited
warranty coverage for the Stainless Steel fryer vats are as follows: (1) Vats that fail due to faulty workmanship or materials
within the rst twelve (12) months from the date of initial start up will be exchanged at no cost. Standard delivery ground
freight will be prepaid by Ultrafryer Systems for rst year failures only. The cost of labor to install the replacement vat will
be covered by Ultrafryer Systems for vats, which fail within twelve (12) months from the date of initial start up. Labor for vat
replacements after the rst year is the responsibility of the owner.
(2) Vats that fail within the rst (18) months will be exchanged at a cost not to exceed $100.00 FOB San Antonio. (3) Vats
that fail within the rst (24) months will be exchanged at a cost not to exceed $150.00 FOB San Antonio. (4) Vats that fail
within the next (8) years will be exchanged at a cost not to exceed $200.00 FOB San Antonio. (Subject to ination adjusted in
accordance with the C.P.I.). Proper credit issue for vat failures is contingent upon receipt, by Ultrafryer Systems, of the serial
number identication tag for any failed vat.
ULTRAFRYER PARTS – All parts on the Ultrafryer® are covered for a period of one (1) year from the initial date of start
up. This is to include computers, gas valves, switches, thermostats, etc. Ultrafryer Systems reserves the right to charge for
certain parts such as computers, lter pumps and motors or any item over the amount of $100.00 until Ultrafryer Systems
receives the defective part back. After inspection, credit for the part will be issued to the purchaser provided the part is
deemed defective and that defect is not the result of neglect or abuse by the user. The shortening ltration system, (hoses)
are warranted for ninety (90) days from the initial date of start up.
PROCESSING WARRANTY CLAIMS – The equipment owner must promptly notify Ultrafryer Systems Warranty
Department of any alleged defects as soon as they are discovered by calling 1-800-525-8130. After such notice, the War-
ranty Department will perform its obligation under this warranty within a commercially reasonable period of time. If alleged
defects develop after normal business hours, on weekends or on holidays the owner must call Ultrafryer Systems rst at the
above number. This number is monitored 24 hours a day, 7 days a week. Ultrafryer Systems will notify an authorized service
agent to make repairs during normal hours or after hours. Any parts that need to be shipped back to Ultrafryer Systems will
be shipped back prepaid by the customer marked with the processing number and to the attention of the WARRANTY
DEPARTMENT.
NON WARRANTY COVERAGE – This warranty does not include coverage for any consequential cost of damages
including, but not limited to, any loss in store sales, spoiled food products, transportation, duty or custom cost. This warranty
does not cover the Ultrafryer® exported to countries outside the United States and its territories. This warranty does not cover
original installation and adjustments such as leveling, calibrations, electrical and gas connections, or problems due to faulty
or contaminated gas supply. This warranty does not cover travel over 100 miles or 2 hours driving time from the location of
the Ultrafryer® or overtime or holiday charges unless the Warranty Department granted prior approval. This warranty does
not cover damage due to misuse, abuse, alteration or accident. This Warranty does not cover improper or unauthorized repair
or installation, damage in shipment, normal maintenance items such as gaskets, hoses, and exterior nishes. Ultrafryer Sys-
tems reserves the right to void component part warranty on any Ultrafryer® that is stored more than 6 (six) months
after shipment from Ultrafryer Systems and not put into service.
LABOR COVERAGE – The cost for labor to replace parts are covered for one (1) year after the initial start up. This war-
ranty will include the labor involved in the six (6) month and the twelve (12) month fryer inspections recommended by the
manufacturer for the rst year after initial start up. The Warranty Department must be promptly notied of any defects
within the rst year of operation. The labor warranty does not include the cost to repair or clear dirty lter systems or per-
form any adjustments that would normally fall under the tasks associated with a proper start up and/or demonstration. Labor
is covered by Ultrafryer Systems for repairs by an AUTHORIZED service agent. Owner is responsible for all costs
associated with fryer installation and start up unless prior arrangements have been made with Ultrafryer Systems.
DISCLAMIER OF WARRANTIES
Other than as stated herein ULTRAFRYER SYSTEMS makes no warranty of any kind, express or implied, including but not
limited to any warranty of merchantability of tness for a particular purpose, including trade usage. Ultrafryer Systems sole
obligation, and purchaser’s sole remedy, under this warranty is repair or replacement, at the discretion of Ultrafryer Systems, of
any part or component that proves to be defective in materials or workmanship. In no event shall Ultrafryer Systems be liable for
consequential, incidental, or special loss or damages arising from the use of, or inability to use, the ULTRAFRYER®. This limited
warranty is the only and complete statement with respect to warranties of NEW Ultrafryer® PAR-2, PAR-3 Gas and Electric
ULTRAFRYERS® sold after March 1st, 2001. There are no other documents or oral statements for which Ultrafryer Systems will
be responsible.
2
SAFETY
The major safety factor associated with the Ultrafryer ZRT3-H Gas Fryer is burns from hot shortening. In order to pre-
vent serious burns, good houskeeping habits are required. The oor in front of and the area around the fryer should be kept
clean and dry. Whenever anything is placed in to a fryer vat, care should be used not to splash the hot shortening. Product
should always be “PLACED” into the shortening, NOT THROWN. Safety googles, neoprene insulated gloves and an apron
must be worn while ltering or boiling-out a fryer vat. Electrical controls on all Ultrafryer Fryers operate on 120 volts single
phase electrical power. No adjustments or replacement of electrical controls should ever be attempted without rst disconnet
ing
electrical power. The fryer should never be operated with wet hands or while standing in water. To do so can result in serious
electrical shock or death.
The Ultrafryer Model ZRT3-H is equipped with the following safety features:
1) High limit thermostat to shut off gas to the burners by opening a solenoid-actuated safety valve in the combination
gas control valve.
2) Combination gas control valve which includes a built-in pressure regulator and manual valve.
3) An air pressure switch to open the 24 volt electrical circuit to the combination gas control valve, turning gas to the
fryer OFF, should the Blower Motor fail.
4) Sensing circuit within the Spark Ignitor module to turn gas to the fryer OFF if a burner FLAME OUT occurs.
5) A Drain Valve Safety Switch and a Default-to-Off circuit in the Default-to-Manual-Restart (DTMR) Control that
will DISABLE the fryer each time the drain valve is OPENED.
DESCRIPTION / SPECIFICATIONS
The Ultrafryer Model ZRT3-H Gas Fryer is constructed from 16 & 18 gauge, type 304 polished satin nish stainless steel.
Most Models are equipped with a Default-To-Manual-Restart (DTMR) Control or an Ultrastat 11 Cooking Computer; however
customers may request the fryer be equipped with an Ultrastat 21 or Ultrastat 25 Cooking Computer. In addition, the 14” &
18” Model ZRT3-H are equipped with the NEWLY developed EZ Dock Filtration System that uses a stainless steel Filter
Screen. The Customer has the option of ordering a Magnepad Filter Screen that uses an impregnated Paper Filter Pad in lieu
of the S/S lter screen. The dimensions specication and gas rating of the 14 & 18” Model ZRT3-H Gas Fryer are as follows:
ULTRAFRYER MODEL ZRT3-H GAS FRYER
DIMENSIONS & OPERATIONAL REQUIREMENTS
SPECIFICATION ITEM 14” ZRT3-H 18” ZRT3-H
Overall Width 15s”” (397 mm) 19” (502 mm)
Overall Depth 25” (641 mm) 37” (940 mm)
Work Height 35” (908 mm) 35” (908 mm)
Oil Capacity High Level
Low Level
35 Lbs (17.5 Liters)
45 Lbs (22.5 Liters)
110 Lbs (55 Liters)
70 Lbs (35 Liters)
Size Vat Container 14” x 14” (356 x 356 mm) 18” x 18” (457 x 457 mm)
Gas Valve Setting Butane Gas
Natural Gas
Propane Gas
10.0” (254 mm) W.C.
4.0” (102 mm) W.C.
10.0” (254 mm) W.C.
10.0” (254 mm) W.C.
4.0” (102 mm) W.C.
10.0” (254 mm) W.C.
Orice Drill Size Butane Gas
Natural Gas
Propane Gas
# 36
# 16
# 32
# 36
# 10
# 32
Gas Rating Butane Gas
Natural Gas
Propane Gas
90,000 BTU/hr (99 MJ/hr)
90,000 BTU/hr (99 MJ/hr)
90,000 BTU/hr (99 MJ/hr)
110,000 BTU/hr (121 MJ/hr)
110,000 BTU/hr (121 MJ/hr)
110,000 BTU/hr (121 MJ/hr)
Inlet Gas Required Butane Gas
Natural Gas
Propane Gas
28.13 FT3/hr (.80 M3/hr)
85.71 FT3/hr (2.43 M3/hr)
36.00 FT3/hr (1.02 M3/hr)
34.38 FT3/hr (.97 M3/hr)
104.70 FT3/hr (2.96 M3/hr)
44.00 FT3/hr (1.25 M3/hr)
Shipping Cube 9.0 FT3 (.26 M3)16.72 FT3 (.47 M3)
Shipping Weight 215 lbs (113 kgs) 315 lbs (142 kgs)
Energy Input 120 Volt 6 Amp 60 Hz 1 Ø 120 Volt 6 Amp 60 Hz 1 Ø
NOTE: TEST START-UP, OPERATIONS, COOKING, FILTERING, AND BOIL OUT PROCEDURES OF A 14” (356MM) OR
18” (457MM) MODEL ZRT3-H GAS FRYER IN THIS MANUAL ARE BASED ON A DEFAULT-TO-MANUAL-RESTART
(DTMR) CONTROL & ULTRASTAT 11 COOKING COMPUTER. REFER TO MANUAL PN 30A009, ULTRASTAT 21
COOKING COMPUTER OPERATOR INSTRUCTIONS; OR MANUAL PN 30A051, ULTRASTAT 25 COOKING COM-
PUTER OPERATION INSTRUCTIONS TO PERFORM THESE FUNCTIONS IF A ZRT3-H FRYER WITH A COOKING
COMPUTER OTHER THAN THAT LISTED IN THIS MANUAL.
3
14” MODEL ZRT3-H
GAS FRYER
18” MODEL ZRT3-H
GAS FRYER
14” & 18” MODEL ZRT3-H GAS FRYER
CONTROL LOCATIONS
4
MODEL ZRT3-H GAS FRYER
5
OPERATING CONTROLS: The “basic” ZRT3-H gas fryer is equipped with an Electronic Thermostat and
Default-to-Manual-Restart (DTMR)
control; however customers may request the fryer be equipped with an “optional” Ultrastat Cooking Com-
puter, such as an Ultrastat 25 Cooking Computer shown below. When applicable, operating instructions for the Ultrastat Cooking Computer
will be provided with the fryer. Operating controls on the Model ZRT3-H gas fryer include the Toggle ON/OFF Switch, AMBER
Power Indi-
cator Lamp, RED Burner Indicator Lamp, and the applicable Temperature Controller. These controls are mounted on the Temperature
Control
Access Panel; and the Electronic Thermostat and other fryer controls are located behind the access door. The main drain valve and shortening
return levers are located behind the Temperature Control Door. These controls were identied in the illustrations shown on the previous page.
AUTOMATIC SAFETY FEATURES:
A. High limit thermostat to shut off gas to the main burners by opening a solenoid-actuated safety valve in the combination gas
control valve.
B. Combination gas control valve which includes a built-in pressure regulator and manual valve.
C. Sensing circuit within the spark ignitor module to turn gas to the fryer OFF if a burner FLAME OUT occurs.
D. A Drain Valve Safety Switch and a Default-to-Off circuit in the Default-to-Manual-Restart (DTMR) Control that will DIS-
ABLE the fryer each time the drain valve is OPENED.
E. An AIR PRESSURE switch to open the electrical circuit and will turn the gas to the fryer OFF in the event the blower
motor fails.
RATING PLATE: Information on this plate includes the model and serial number; BTU/HR input rating of the burners; gas mani-
fold pressure in inches W.C. ; minimum inlet gas
required, orice size; and type of gas. This data is essential for proper identica
tion when communicating
with ULTRAFRYER SYSTEMS or requesting special parts or information.
THE FRYER MUST BE CONNECTED ONLY TO THE TYPE OF GAS IDENTIFIED ON THIS RATING PLATE!
6
INLET GAS LINE REQUIREMENTS
PIPE
LENGTH
PIPE DIAMETERS (inches & (mm equivalents))
Maximum Allowable Flow (Shown in ft3/hr (M3/hr))
Feet
(Meters)
15
(4.6)
62
(1.7)
108
(4.7)
350
(9.8)
620
(17.4)
960
(26.9)
2,000
(56.0)
3,500
(98.0)
5,400
(151.2)
11,200
(313.6)
30
(9.1)
43
(1.2)
120
(3.4)
245
(6.9)
430
(12.0)
680
(19.0)
1,400
(39.2)
2,450
(68.6)
3,800
(106.4)
7,900
(221.2)
45
(13.7)
35
(1.0)
98
(2.7)
200
(5.6)
355
(9.9)
530
(14.8)
1,150
(32.2)
2,000
(56.0)
3,200
(89.6)
7,900
(182.0)
60
(18.3)
30
(0.8)
84
(2.4)
175
(4.9)
310
(8.7)
480
(13.4)
1,000
(28.0)
1,760
(49.3)
2,700
(75.6)
5,600
(156.8)
75
(22.9)
27
(0.8)
76
(2.1)
155
(4.3)
275
(7.7)
430
(12.0)
890
(24.9)
1,560
(43.7)
2,450
(68.6)
5,000
(140.0)
90
(27.4)
25
(0.7)
70
(2.0)
145
(4.1)
250
(7.0)
395
(11.1)
810
(22.7)
1,430
(40.0)
2,260
(63.3)
4,550
(127.4)
105
(32.0)
23
(0.6)
64
(1.8)
132
(3.7)
232
(6.5)
370
(10.4)
(750
(21.0)
1,300
(36.4)
2,100
(58.8)
4,200
(117.6)
120
(36.6)
21
(0.6)
60
(1.7)
125
(3.5)
215
(6.0)
340
(9.5)
700
(19.6)
1,200
(33.6)
1,950
(54.6)
4,000
(112.0)
150
(45.7)
19
(0.5)
54
(1.5)
110
(3.1)
195
(5.5)
310
(8.7)
630
(17.6)
1,080
(30.2)
1,750
(49.0)
3,550
(99.4)
180
(54.9)
17
(0.5)
49
(1.4)
100
(2.8)
175
(4.9)
280
(7.8)
570
(16.0)
960
(26.9)
1,600
(44.8)
3,200
(89.6)
210
(64.0)
16
(0.4)
44
(1.2)
94
(2.6)
165
(4.6)
260
(7.3)
530
(14.8)
890
(24.9)
1,450
(40.6)
3,000
(84.0)
240
(73.2)
15
(0.4)
43
(1.2)
88
(2.5)
155
(4.3)
240
(6.7)
500
(14.0)
840
(23.5)
1,350
(37.8)
2,800
(78.4)
270
(82.3)
14
(0.4)
40
(1.1)
83
(2.3)
145
(4.1)
230
(6.4)
470
(13.2)
780
(21.8)
1,300
(36.4)
2,650
(74.2)
300
(91.4)
14
(0.4)
38
(1.1)
79
(2.2)
138
(3.9)
215
(6.0)
440
(12.3)
750
(21.0)
1,250
(35.0)
2,500
(70.0)
450
(137.2)
11
(0.3)
31
(0.9)
64
(1.8)
112
(3.1)
176
(4.9)
360
(10.1)
630
(17.6)
1,000
(28.0)
2,050
(57.4)
600
(182.9)
10
(0.3)
27
(0.8)
56
(1.6)
97
(2.7)
152
(4.3)
315
(8.8)
530
(14.8)
860
(24.1)
1,750
(49.0)
NOTE: 1) FT3/HR (M3/HR) values may vary due to heating value and specic gravity of gas supplied by local companies.
2) To determine the inlet gas line diameter for the distance between the fryer and main gas regulator, locate the FT3/HR (M3/HR) of gas required for the fryer and
pipe length and read the pipe diameter on the top row. For example: a 14” ZRT3-H fryer operating on NATURAL GAS requires 85.71 FT3/HR (2.43 M3/HR)
of gas at the fryer’s inlet gas manifold. If the fryer bank is located 60 feet from the building gas regulator, a 1” (25mm) diameter gas line MUST be installed
between the manifold and regulator.
”
(13 mm)
”
(19mm)
1”
(25mm)
1”
(32mm)
1”
(38mm)
2”
(51mm)
2”
(64mm)
3”
(76mm)
4”
(102mm)
INLET GAS LINE SIZING - The Table below is to be utilized to calculate the size (diameter) of the inlet gas line from the building regulator to
the fryer manifold.
NOTE:
The exible gas line used to connect the gas manifold to the building gas supply line must rated for the BTU/Hr (MJ/Hr) for the Fryer.
For example:
the BTU/Hr (MJ/Hr) rating for a ZRT3-H fryer is 90,000 BTU/Hr (99 MJ/Hr) and therefore would require a ” diameter
gas line.
INLET GAS REQUIREMENTS
MODEL ZRT3-H-3 GAS FRYERS
14” (356)
Butane
Natural
Propane
10.0 (254)
4.0 (102)
10.0 (254)
#36
#16
#32
90,000 (99.0)
90,000 (99.0)
90,000 (99.0)
28.13 (0.80)
85.71 (2.43)
36.00 (1.02)
VAT SIZE
Model ZRT3-H
IN MM
GAS TYPE
GAS VALVE SETTING (WC)
IN MM ORIFICE HOLE
SIZE
RATING
BTU/HR MJ/HR
INLET GAS REQ’D
FT3/HR M3/HR
NUMBER DESCRIPTION RATING
BTU/HR (MJ/HR)
24-322 ” (19mm) Diameter Flexible Gas Line (w/quick connect
couplings) 48” (1219mm) long. Connect-It SSGC75-48-UCQ 225,000 (281)
24-323 1” (25mm) Diameter Flexible Gas Line (w/quick connect
couplings) 48” (1219mm) long. Connect-It SSGC100-48-UCQ 435,000 (459)
24-456 1” (32mm) Diameter Flexible Gas Line (w/quick connect
couplings) 48” (1219mm) long. Connect-It SSGC125-48-UCQ 875,000 (923)
FLEXIBLE GAS LINES STOCKED BY ULTRAFRYER SYSTEMS
INLET GAS REQUIREMENTS
The Flexible Gas Line used to connect the gas manifold to the building gas supply line must be rated for the BTU/Hr (MJ/Hr) designated for the
Fryer. Flexible gas lines and their ratings stocked by Ultrafryer Systems are listed below:
PRE-INSTALLATION: Safe and satisfactory operation of a Model ZRT3-H gas fryer depends on its proper installation. Installation must conform
to local codes or, in the absence of local codes, with the current National Fuel Gas Code ANSI Z223.1 (latest edition). In Canada, gas installa-
tion shall be in accordance with the current CAN/CGA B 149.1 and .2 installation codes and/or local codes.
GENERAL: Each Model ZRT3-H fryer should be installed as follows:
A. Placed beneath a properly designed exhaust hood
B. Installed by a licensed plumber.
C. Connected to the type gas for which the unit was fabricated as shown on the rating plate.
D. Connected to the proper size pressure regulator installed in the gas supply line and adjusted to the proper manifold pressure.
E. Connected to the main gas supply line with the proper size supply line.
F. Restrained by use of a restraining device to avoid splashing of hot liquid and to assure tension cannot be placed on the exible gas line or
ttings.CLEARANCES: The appliance must be kept free and clear of all combustibles. The minimum clearance from combustible and
non-combustible construction is 6” (152 mm) from the sides, and 6” (152 mm) from rear. The fryer may be installed on combustible oors.
NOTE: Adequate clearances must be provided for servicing and proper operation.
STANDARDS: Installation must be planned in accordance with all applicable state and local codes, taking into account the following standards
:
A. The fryer and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that
system at pressures in excess of psig (3.45kPa). In Canada, gas installation shall be in accordance with the current CAN/CGA B 149.1
and .2 installation codes and/or local codes.
B. The fryer must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing of the gas supply
piping system at pressures equal to or less than psig (3.45kPA).
C. When installed the fryer must be electrically grounded in accordance with local codes, or in the absence of local codes, in accordance with the current
National Electrical code ANSI/NFPA 70 (latest edition). In Canada electrical installation must be in accordance with the current CSA C22.1 Canadian Elec-
trical Code and/or local codes.
D. Other applicable nationally recognized installation standards such as:
1. National Fuel Gas Code ANSI Z223.1 (latest edition)
American Gas Association
1515 Wilson Blvd.
Arlington, VA22209
2. NFPA Standards #54, #94 and #221 (latest edition)
National Fire Protection Association
470 Atlantic Avenue
Boston, MA 02110
3. ANSI Z21.69/CAN/CGA-6.16 AND Z21.41/CAN1 6.9
E. Exhaust hood, when installed must conform to the current NFPA 54-1 and Canadian CAN/CGA-1.11 (latest edition)
NOTE: Local building codes will usually not permit a fryer with its open tank of hot oil to be installed immediately next to an open ame
of any type, whether a broiler or an open burner or range. Check local codes before beginning installation.
AIR SUPPLY AND VENTILATION: The area around the appliance must be kept clear of any combustible or amable products and avoid any
obstruction to the ow of ventilation air as well as for ease of maintenance and service. NOTHING is to be stored in the interior of the
fryer’s cabinet except the lter tub assembly.
A. A means must be provided for any commercial, heavy duty-cooking appliance to exhaust combustion wastes outside of the building. It is
essential that a fryer be set under a powered exhaust hood or that an exhaust fan be provided in the wall above the unit, as exhaust tempera-
tures are in the vicinity of 400°F (204ºC).
NOTE: Strong exhaust fans in a hood or in the overall air conditioning system can produce slight air drafts in the room, which can interfere
with burner performance and be hard to diagnose. Air movement should be checked during installation and if burner problems persist,
make-up air openings or bafes may have to be provided in the room.
B. Exhaust temperature, in addition to the open tank of hot oil, make the storage of anything on shelving over or behind the fryer unsafe.
C. Filters and drip troughs should be part of any industrial hood, but consult local codes before constructing and installing any hood.
D. Provisions must be made for an adequate supply of fresh air and adequate clearance must be maintained for air openings into the combus-
tion chamber.
RECEIVING & INSTALLING THE FRYER
A. UNPACKING: Check that the container is upright. Use an outward prying motion – DO NOT USE A HAMMER - to remove the
carton. Check the fryer(s) for visible damage; if such damage has occurred do not refuse shipment, but contact the carrier and le the
appropriate freight claims.
B. INSTALLING: Roll the assembled fryer bank into the building, proceed to next paragraph.
WARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE
PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATING AND MAINTENANCE
INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.
LEVELING:
A. When the fryer is placed in its operating location check to be sure it is level. If not, loosen the casters and insert the appropriate number
of shim plates between leg and caster plates then retighten the caster bolts.
B. If the oor is smooth and level, adjust to the high corner and measure with a spirit level. If the oor is uneven or has a decided slope,
level the unit with metal shims.
NOTE: A caster may not return exactly to the same position after being moved, which may require re-leveling after each move.
7
8
INLET GAS REQUIREMENTS:
SIZE GAS TYPE GAS VALVE
H2O COLUMN SETTING
ORIFICE
HOLE SIZE
HEATING
RATING INLET GAS REQUIRED
14”
Butane Gas
Natural Gas
Propane Gas
10.0” (254mm) W.C.
4.0 “ (102mm) W.C.
10.0” (254mm) W.C.
#36
#16
#32
90,000 BTU/HR (99.0 MJ/HR)
90,000 BTU/HR (99.0 MJ/HR)
90,000 BTU/HR (99.0 MJ/HR)
28.13 ft3/hr (.80 M3/hr)
85.71 ft3/hr (2.43 M3/hr)
36.00 ft3/hr (1.02 M3/hr)
18”
Butane Gas
Natural Gas
Propane Gas
10.0” (254mm) W.C.
4.0 “ (102mm) W.C.
10.0” (254mm) W.C.
#36
#10
#32
110,000 BTU/HR (121 MJ/HR)
110,000 BTU/HR (121 MJ/HR)
110,000 BTU/HR (121 MJ/HR)
34.38 ft3/hr (.97 M3/hr)
104.70 ft3/hr (2.96 M3/hr)
44.00 ft3/hr (1.25 M3/hr)
GAS CONNECTION: The gas supply (service) line must be the same size or greater than the inlet line of the appliance. THE GAS SUPPLY
LINES MUST BE SIZED TO ACCOMMODATE ALL THE GAS FIRED EQUIPMENT THAT MAY BE CONNECTED TO THAT
SUPPLY. Refer to the Inlet Gas Line Sizing Table on page 4.
NOTE: Sealant used on all pipe joints must be resistive to butane and propane gas.
A. Manual shut off valve: This supplier-installed valve must be installed in the gas service line ahead of the appliance and in a position where
it can be reached quickly in the event of an emergency.
B. Pressure regulator: All commercial cooking equipment must have a pressure regulator on the incoming service line for safe and efcient
operation, because service pressure may uctuate with local demand. External regulators are not required on this fryer, as that function is
performed by a combination gas control valve, however if the incoming pressure is in excess of psig, a step-down regulator will be
required.
C. Natural gas: Natural gas fryers require 7” (178mm) water column (W.C.) “inlet” pressure to the fryer’s combination gas control valve for
proper operation, when all gas units are operating simultaneously. Butane and Propane gas fryers require 14” (356mm)water column (W.C.)
“inlet” pressure to the fryer’s combination gas control valve for proper operation, when all gas units are operating simultaneously. This
“inlet” pressure MUST be checked with a manometer PROIR to placing the fryer in operation.
WARNING: IF THE “INLET” GAS PRESSURE AT THE FRYER’S COMBINATION GAS CONTROL VALVE “EXCEEDS” lb/in2
(.035 kg/cm2) OR APPROXIMATELY 14” (356 mm) W.C., AN EXTERNAL REGULATOR MAY BE NEEDED TO PREVENT
DAMAGE TO THE COMBINATION GAS VALVE, AND VOIDING OF WARRANTY. FAILURE TO ADDRESS THIS COULD
RESULT IN EXPLOSION OR FIRE.
D. Combination gas control valve: The correct combination gas control valve and orice is installed at the factory for BUTANE, NATURAL
and PROPANE units based on each Purchase Order. This valve should be CHECKED/ADJUSTED by qualied service personnel using
proper test equipment for the following “OUTLET” gas pressure PRIOR to start-up of a fryer. NATURAL GAS FRYERS 4” (102mm)
W.C. BUTANE/PROPANE FRYERS 10” (254mm) W.C.
E. Rigid connections: Check any installer-supplied intake pipe(s) visually and/or blow them out with compressed air to clear dirt particles,
threading chips or any other foreign matter before connecting to the service line as these Model ZRT3-Hticles may clog the orice when
gas pressure is applied. All connections must be tested with a soapy solution before lighting the fryer.
DO NOT USE AN OPEN FLAME
TO
CHECK FOR LEAKS! Putting an open ame beside a new connection is not only dangerous, but will often miss small leaks that a
soapy solution would nd.
C. Connect the gas manifold to the building gas supply line by means of a CSA International APPROVED exible gas line as shown in the
gure below.
NOTE: CONNECT-IT inc. ” (19mm), 1” (25mm) and 1 ” (32mm) exible gas hose 4 feet long (1219mm) with a quick disconnect coupling
on one end is available from Ultrafryer Systems under PN 24-322 (” (19mm) hose), PN 24-323 (1” (25mm) hose) and PN 24-456 (1 ”
(32mm) hose). These hoses are euipped with a fusible link, which melts at 361°F (183ºC) that will SHUT OFF the gas supply when it melts.
A restraining device 44” (1119mm) long is also available under PN 24-324.
CAUTION: THE BUILDING GAS SUPPLY LINE MUST BE SIZED TO PROVIDE THE VOLUME OF GAS REQUIRED FOR PROPER OPERATION
AS EXPLAINED ON THE PREVIOUS PAGE.
WARNING: THE RESTRAINT DEVICE (ITEM 9) MUST BE INSTALLED TO ASSURE TENSION CANNOT BE PLACED ON THE
FLEXIBLE GAS LINE OR FITTING.
1. BUILDING GAS SERVICE LINE 6. APPLIANCE MANIFOLD/NIPPLE
2. MAIN GAS CUT-OFF VALVE 7. EYELET FASTENERS
3. CONNECT-IT QUICK-DISCONNECT 8. SPRING HOOK
4. FLEX-CON CONNECTOR 9. RESTRAINING CHAIN
5. ELBOW
TYPICAL GAS CONNECTION
9
F. Flexible Couplings, Connectors: The installation is to be made with a connector that (1) complies with the Standard for Connectors for
Movable Gas Appliances, ANSI Z21.69 (CAN/CGA-6.16), and a quick-disconnect device that complies with the Standard for Quick-
Dis-connect Devices for Use With Gas Fuel, ANSI Z21.41 (CAN1-6.9) (2) adequate means must be provided to limit the movement of
the appliance without depending on the connector and the quick dis-connect device or its associated piping to limit the appliance movement
and (3) the location(s) where the restraining means may be attached 6to the appliance shall be specied.
DOMESTIC CONNECTORS ARE NOT SUITABLE!!!
G. Fryer Service: The fryer is equipped with swivel casters. To service the fryer:
1) Turn “OFF” gas supply at the supply source.
2) Disconnect the exible gas line quick-disconnect
3) Disconnect restraint means and roll fryer out for rear service access.
4) When the fryer is re-positioned, be sure to reconnect the restraint and level the fryer.
ELECTRICAL CONNECTION: The MAXIMUM current draw per vat at Initial Start-up or during a Warm-up Cycle will be 3 Amperes
at 120 Volts. When running the Filter System simultaneously allow for an additional 3 Amperes. Refer to the wiring diagram attached to the
front door of the fryer for internal electrical connections.
DEFAULT-TO-MANUAL-RESTART (DTMR) CONTROL: The “basic” Model ZRT3-H gas fryer is equipped with a Default-to-Manual-
Restart (DTMR) Control. This control contains a Default-to-Off electrical circuit that DISABLES a fryer any time the drain valve is OPENED,
and a Default-to-Melt electrical circuit which automatically places a fryer in a shortening MELT MODE to gradually and SAFELY
melt shortening each time a fryer is truned ON and the START BUTTON is drepressed on the DTMR control. The Default-to-Manual-Restart
Control is intended to avoid “operator errors” that can result is DRY FIRING a fryer causing shortening to be scorched, heat exchanger damage
and/or a vat re.
DTMR CONTROL PANEL
BLUE READY TO START LAMP - When lit indiacates the power on/off
switch is in the ON position, the drain valve is CLOSED, and the fryer is
ready to operate.
START BUTTON - When this button is momentarily depressed, it places
the fryer in operation.
RED STARTED LAMP - When lit indicated the START BUTTON has been
momentarily depressed and the fryer is operating.
AMBER MELT MODE LAMP - When lit indicated the TIMER in the Default-
To-Melt circuit is cycling the fryer burner ON for seven (7) seconds and OFF
for 28 seconds to safely heat shortening.
EXIT MELT BUTTON - When this button is momentarily depressed the TIMER in the Default-To Melt circuit will switch to the FULL ON
position allowing the Fenwal thermostat to heat shortening to its pre-set temperature.
OPTIONAL CONTROLS : The Model ZRT3-H gas fryers may be equipped with
an Ultrastat Model 11, 21, or 25 Cooking Computer as described below:
A. ULTRASTAT 11 COOKING COMPUTER: Some Model ZRT3-H-3 gas fryers
are equipped with an Ultrastat 11 Cooking Computer which is connected to the
fryer’s electrical system to serve as its thermostat as well as providing heat control,
status information and product cook timer. When the computer is in operation it will
DISABLE the fryer if the drain valve is OPENED. Operation of the Ultrastat 11
Cooking Computer is covered in the Ultrastat 11 Ultrafryer Computer Operation
Instrutction PN
30A053 provided with Fryeres equipped with that Cooking
Com
puter.
B. ULTRASTAT 21 COOKING COMPUTER: The Ultrastat21 Cooking
computer is in compliance with the limits for a class B computing device
pursuant to Sub-Part J of Part 15 of the FCC Rules. This cooking computer
is cap-able of cooking up to eight (8) different products; each of which can be
programmed to be cooked from one (1) to ten (10) different temperature at
different times in a cook cycle. In addition, the operator can program the
ULTRASTAT21 computer to cook products under “FLEX” or STRAIGHT”
timing modes. When programmed for “FLEX” time mode the computer
will adjust the actual cook time taking into con-sideration the temperature
variation due to load size, initial product temperature, product moisture
content, and other factors that affect the cook cycle. Under “STRAIGHT”
time mode, the product is cooked at a specied temperature for the length
of time programmed without adjusting for these variations. Operation of the
ULTRASTAT21 cooking computer is covered in the ULTRASTA21 Gas
Fryer Computer Operation Instructions PN 30A009 provided with fryers
equipped that computer.
10
C. ULTRASTAT 25 : The Ultrastat 25 Cooking Computer is a high perform-
ance, micro-processor based electronic controller designed for use in com-
ercial appliance temperature and timing control applications. Utilizing a
microcontroller board, membrane switch front panel with a digital LED
readout, and display board, the Ultrastat 25 Cooking Computer has been
customized for Ultrafryer Systems applications by the addition of up to (10)
stage cooking proles for each of the (8) product keys, exit melt feature,
optional temperature setback and ltering promps, and can be programmed
to cook products under “Flex” or “Straight” timing modes. Operation of the
Ultrastat 25 Cooking Computer is covered in its Instruction Manual PN
30A051 provided with Fryers Equipped with that computer.
INITIAL START-UP
A. CLEANING: New units are wiped clean with solvents at the factory to remove any visible signs of dirt, oil, grease, etcetera, remaining
from the manufacturing process, then given a light coat of oil. Each fryer vessel should be thoroughly washed with hot soapy water to
remove lm residues, installation dust or debris; and then wiped dry before being used for food preparation.
B. START-UP: The fryers are tested, adjusted and calibrated prior to being shipped: however adjustments may be necessary on installation to
meet local conditions, high or low gas pressure, differences in altitudes, variations in gas characteristics and to correct possible problems
caused by rough handling or vibration during shipment. Initial calibration or adjustment is the responsibility of the customer and will not
be covered bythe Ultrafryer Systems warranty.
NOTE: Calibration and adjustments must be performed by qualied personnel.
C. LIGHTING INSTRUCTIONS: Each fryer is equipped with a spark ignition system and to test this system, perform the following steps,
in sequence:
1. Turn the Toggle ON/OFF SWITCH to the OFF position.
2. Fill the fryer vessel with hot or cold water to the SHORTENING LEVEL mark.
CAUTION : IF THE MAIN BURNERS ARE OPERATED WITH THE VESSEL EMPTY, THE HEAT WILL CAUSE THE JOINTS OF THE
FRYER VESSEL TO BE PLACED UNDER UNDO STRESS AND MAY CAUSE THE HEAT EXCHANGER VESSEL TO WARP OR
BUCKLE, VOIDING WARRANTY.
3. Turn the manual gas valve behind the fryer control access door of the fryer to the OFF position and wait FIVE (5) minutes for any
accumulated gas to disperse.
4. ENSURE the MAIN gas shut-off is in the ON position, MANUAL VALVE on the combination GAS CONTROL VALVE (located
behind the fryer control access door) is in the ON position and the EXHAUST FAN in ON.
5. Turn the manual gas valve to the ON position.
6. Turn the ON/OFF switch ON; then place the DTMR or ULTRASTAT Cooking Computer into the MELT MODE.
WARNING!!! DO NOT USE A MATCH OR CANDLE TO LIGHT A FRYER… EVER!
SEQUENCE OF IGNITION:
When the lighting instruction steps are performed in the sequence listed above, the following will occur:
A. Blower motor will come ON activating the air pressure switch.
B. The air pressure switch will CLOSE completing the electrical circuit to the transformer.
C. The transformer will supply 24 volts to the IGNITOR MODULE and GAS CONTROL VALVE, and the ignitor will SPARK lighting
the gas in the burner.
WARNING!!! WHEN CHECKING FOR BURNER PERFORMANCE, DO NOT STAND WITH YOUR FACE CLOSE
TO THE BURNER…. IT MAY LIGHT WITH A “POP” AND COULD FLASH BACK AND CAUSE FACIAL BURNS.
NOTES: 1) If the burner ame fails, it will be sensed by the SPARK IGNITOR, the Spark Ignitor Module will open the electrical circuit to the
GAS CONTROL VALVE shutting off gas to the burner. 2) If the blower motor fails, the air pressure switch will open the
electrical circuit to the TRANSFORMER removing electrical power from the SPARK IGNITOR MODULE and GAS CONTROL VALVE
shutting off gas to the burner.
BURNER OPERATION TEST: Perform above LIGHTING INSTRUCTIONS and observe operation of the burners. When satised that the
burner is operating properly, drain the fryer vessel of water and dry the vessel thoroughly; then ll the fryer vessel with shortening according to
instruction below.
SHORTENING INSTALLATION:
A. LIQUID SHORTENING: When using a liquid shortening cooking oil) ll the fryer with shortening even with the middle line of the “E ”
in the word LEVEL of the applicable shortening level mark on he rear wall of the fryer.
B. SOLID SHORTENING:
1) Cut a block of solid shortening into small pieces.
2) Place small pieces of solid shortening EVENLY on top of the HEAT EXCHANGER TUBES or THOROUGHLY PACK
these
pieces of solid shortening between, below and above the EAT EXCHANGER TUBES. While packing solid shorten
ing is messy
and time consuming, it is the fastest way to melt solid shortening.
3) Turn the fryer ON/OFF switch to the ON position; then place the DTMR or other fryer control in the MELT MODE.
4) When the BURNER TUBES are completely covered with LIQUID shortening and the shortening temperature has reached the appli-
cable MELT LIMIT TEMPERATURE, replace the grill in the fryer vat; then place the fryer in the FULL ON mode.
5) Continue adding solid shortening as follows:
a) Place small pieces of solid shortening into a fry basket.
b) CAREFULLY lower the basket into the fryer vat.
c) GENTLY turn the basket to allow these pieces of solid shortening to oat away.
d) Repeat the above steps until liquid shortening is even with the middle line of the “E ” in the word LEVEL of the applicable
shortening level mark on the rear wall of the fryer vat.
WARNING!!! TO AVOID INJURY
I DO NOT MOVE A FRYER FILLED WITH HOT LIQUID.
II THE FRYER MUST BE RESTRAINED BY USE OF A RETAINING DEVICE TO PREVENT TIPPING TO AVOID THE
SPLASHING OF HOT LIQUID.
III THE AREA SURROUNDING THE FRYER MUST BE KEPT FREE AND CLEAR OF ALL COMBUSTIBLES.
IV DO NOT GO NEAR THE AREA DIRECTLY OVER THE FLUE OUTLET WHEN THE FRYER’S MAIN BURNERS
ARE OPERATING.
V ALWAYS WEAR OIL-PROOF, INSULATED GLOVES WHEN WORKING WITH A FRYER FILLED WITH HOT OIL.
VI ALWAYS DRAIN HOT OIL INTO A METAL TUB, POT OR CAN … HOT OIL CAN MELT PLASTIC BUCKETS OR
SHATTER GLASS.
START-UP AND COOKING
A. GENERAL :
1. The Default-to-Manual-Restart (DTMR) Control along with a Fenwal
Temperature Controller or Electronic Thermostat is connected to a fryer’s
electrical system to control operation of the fryer. The DTMR contains a
Default-to-Off circuit that will DISABLE the fryer anytime the Drain Valve
is OPEN, and a Default-to-Melt circuit that will automatically place the fryer
in a SHORTENING MELT MODE to gradually and safely heat shortening
each time the fryer’s Toggle ON/OFF Switch is turned ON.
2. Electronic Thermostat: The Electronic Thermostat has a temperature
range from 200ºF (93ºC) to 400ºF (204ºC) and will accurately maintain a
pre-set shortening cook temperature within ± 2º of the pre-set temperature.
B. START-UP :
1. TO TEST OPERATE an Ultrafryer Gas Fryer equipped with a Default-to-Manual-Restart (DTMR) control:
a. Ensure the fryer’s Toggle ON/OFF Switch is in the OFF position.
b. Fill the fryer vat with hot or cold water to the middle of the “E←” in the word LEVEL of the applicable shortening level mark
on the rear of the vat.
c. Turn the MANUAL gas valve to the OFF position and wait FIVE (5) minutes for any accumulated gas to disperse.
d. ENSURE the MAIN gas shut-off valve is in the ON position, and that the EXHAUST FAN is ON.
e. Turn the MANUAL GAS VALVE to the ON position.
f. Perform the following steps, in the order listed:
11
ITEM ACTION DTMR CONDITION
1
ENSURE the drain valve handle is in the CLOSED
UP position and that water is at the proper level; then
turn the Toggle ON/OFF switch to the ON position.
A. BLUE READY TO START lamp will LIGHT.
CAUTION: PRIOR TO PROCEEDING TO STEP 2 VISUALLY CHECK THAT THE HEAT MECHANISM IS
COVERED WITH AT LEAST 2” (51 mm) OF WATER.
2 Depress, then release the momentary START button
A. RED STARTED lamp and AMBER MELT
MODE lamp will light.
B. BLUE READY TO START lamp will turn OFF.
C. A TIMER in the Default-To-Melt electrical circuit
will begin cycling the fryer heat mechanism ON for
seven (7) seconds and OFF for 28 seconds to safe-
ly heat the water.
CAUTION: PRIOR TO PROCEEDING TO STEP 3, VISUALLY CHECK THAT THE WATER
COMPLETELY COVERS THE HEAT MECHANISM.
3
When the shortening temperature is above 100ºF
(38ºC) depress, then release the momentary EXIT
MELT button.
A. AMBER MELT MODE lamp will turn OFF and
the RED STARTED lamp will remain lit.
B. The TIMER in the Default-To-Melt circuit will
switch to the FULL ON position, allowing the
Fenwall thermostat or Electronic Thermostat to
heat water to its pre-set temperature.
4
When the fryer’s RED heat indicator lamp turns
OFF, indicating the pre-set temperature has been
reached, initiate a cook cycle.
Steps 1, 2 and 3 will have to be repeated each time any of the following occurs:
DRAIN VALVE IS OPENED.
TOGGLE ON/OFF SWITHCH IS TURNED OFF TO FILTER SHORTENING.
TOGGLE ON/OFF SWITCH IS TURNED OFF AT CLOSING.
ELECTRONIC THERMOSTAT
2. TO TEST OPERATE a Ultrafryer Gas Fryer equipped with an Ultrastat 11Cooking Computer:
a. Ensure the fryer’s Toggle ON/OFF Switch is in the OFF position.
b. Fill the fryer vat with hot or cold water to the middle of the “E←” in the word
LEVEL of the applicable shortening level mark on the rear of the vat.
c. Turn the MANUAL gas valve to the OFF position and wait FIVE (5) minutes
for any accumulated gas to disperse.
d. ENSURE the MAIN gas shut-off valve is in the ON position, and that the
EXHAUST FAN is ON.
e. Turn the MANUAL GAS VALVE to the ON position.
f. Perform the following steps, in the order listed:
12
STEP ACTION RESPONSE
1
ENSURE the drain valve handle is in the
closed position and that water is at the proper
level; then turn the Toggle ON/OFF switch
to the ON position and turn the Ultrastat
11 Cooking Computer ON by depressing
the ON/OFF key.
A. The AMBER power lamp beside the fryer Toggle
ON/OFF switch will LIGHT.
B. CY P will appear in the Ultrastat 11 Computer
dis
play
to indicate it is in the PURGE MELT MODE
.
C. The Computer will begin cycling the gas burner
ON for 7 seconds and OFF for 28 seconds.
CAUTION: PRIOR TO PROCEEDING TO STEP 2, VISUALLY CHECK THAT THE HEAT EXCHANGERS
TUBES ARE COVERED BY AT LEAST 2” (51 mm) OF WATER.
2When the water begins to BOIL, depress the
EXIT
MELT key.
HEAt
will appear in the computer display to
indicate it is in the FULL ON mode.
3 Depress the TEMP key ONCE. T
he ACTUAL water temperature will be shown
in the computer display
NOTE: DEPRESS THE TEMP KEY A SECOND TIME TO DISPLAY THE SET POINT
TEMPERATURE OF THAT TIMER.
4
Turn the Ultrastat 11 OFF by depressing and
holding the ON/OFF key for 3 SECONDS,
then turn the fryer TOGGLE ON/OFF switch
to the OFF position
The AMBER POWER lamp beside the fryer
TOGGLE ON/OFF switch will turn OFF.
5
After the water in the vat and metal surfaces of
the fryer has COOLED, drain the water into
a oor drain.
3. TO TEST OPERATE a Ultrafryer Gas Fryer equipped with an Ultrastat 21 Cooking Computer, use the procedures con-
tained in the “Ultrastat 21 Gas Fryer Computer Operation Instructions”, PN 30A009, provided with the fryer.
4. TO TEST OPERATE a Ultrafryer Gas Fryer equipped with an Ultrastat 25 Cooking Computer, use the procedures con-
tained in the “Ultrastat 25 Gas Fryer Computer Operation Instructions”, PN 30A051, provided with the fryer.
14” ZRT3-H
FRYER
18” ZRT3-H
FRYER
C. INITIAL CLEANING -
New MODEL ZRT3-H gas fryers are wiped clean with solvents at the factory to remove any visible
signs of dirt, oil
, grease, etc., remaining from the manufacturing process; then given a light coat of oil. Each fryer and lter
system should be THOROUGHLY washed with HOT sanatized solution to remove lm residues, installation dust or debris
and then wiped dry prior to placing the fryer in operation.
D. COOKING : Most products should be cooked with a shortening temperaure about 360ºF (182ºC); however, each product should be
cooked at the LOWEST temperature that produces a high quality product while obtaining maximum usage of the shortening.
I - DO USE A HIGH QUALITY SHORTENING TO ACHIEVE A CONSISTENT QUALITY PRODUCT AND LONG TERM
SAVINGS.
II - DO NOT SALT PRODUCTS OVER THE FRYER AS SALT QUICKLY DETERIORATES THE SHORTENING AND
FLAVORS OTHER PRODUCTS COOKED IN THE SAME SHORTENING.
III - DO FILTER SHORTENING AFTER THE LUNCH AND DINNER RUSH AND MORE OFTEN IN A HIGH SALE VOLUME
STORE; AND BOIL-OUT THE FRYER EVERY 7 DAYS.
OPERATING INSTRUCTIONS: The Model ZRT3-H gas fryer is equipped with a shortening lter system which is to be operated and
cleaned according to the operating section of this manual.
A GENERAL:
1. SHORTENING: Use a high quality shortening to achieve a consistent quality product as well as a long term savings.
2. SHORTENING TEMPERATURE: Most products should be cooked with a shortening temperature about 350°F (177ºC); however, each
product should be cooked at the LOWEST temperature that produces a high quality product while obtaining maximum usage of the
shortening.
3. SALTING: Products should not be salted over the fryer vessel as salt quickly deteriorates the shortening and avors other products
cooked in the same shortening.
4. POWER FAILURES: The Model ZRT3-H fryer cannot be operated during power failures. DO NOT attempt to by pass safety controls
and manually operate the fryer.
5. PUMP MOTOR: The lter pump motor is protected by a motor thermal overload switch.
CAUTION: ENSURE THE WASH DOWN HOSE IS NOT CONNECTED TO A FRYER PRIOR TO RESETTING A THERMAL
OVERLOAD SWITCH.
B FILTERING SHORTENING: The fryer must be ltered al least twice a day (once after the lunch rush and again after the dinner rush).
Place the amount of lter agent in the shortening as prescribed by the chemical supplier and follow instructions for ltering shortening pro-
vided in the operating section of this manual.
C LEVELING SHORTENING: After ltering, the shortening level must be checked and fresh shortening added when necessary.
1. The shortening in the vat should reach to the middle line of the “E ” in the word LEVEL of the applicable shortening level mark
on the
rear wall of the fryer.
2. If shortening is needed, use the lter scraper to cut off a small block of solid shortening.
3. Place the small block of shortening into a fry basket, lower the basket into the shortening; then turn the basket to allow the block to oat
freely.
4. Repeat the above steps until the shortening in the vat is at the proper level.
D BOILING OUT FRYER: The fryer should be BOILED OUT every 7 DAYS to remove carbon buildup and other encrusted materials. Add
the amount of boil out compound to the fryer as prescribed in the cleaning manual provided by the chemical supplier and follow instructions for
boiling out a fryer in the operating section of this manual.
E CLOSING/SHUTDOWN INSTRUCTIONS:
1. CLOSING: When closing at night; lter the shortening in the fryer, THOROUGHLY drain all lter lines and cover the fryer vessel.
Turn the ON/OFF Switch on the fryer OFF and turn the Manual Gas Valve OFF.
2. SHUTDOWN OR PROLONGED POWER FAILURE:
a. Shutdown: Perform the following whenever a fryer is being shutdown for an extended period of time:
1) Drain and discard the shortening.
2) THOROUGHLY clean the fryer vat.
3) Turn the ON/OFF Switch to the OFF position, disconnect the 120-volt power cord and turn applicable Circuit Breakers OFF.
4) Turn the Manual Gas Valve OFF.
b. Prolonged power failure: The Model ZRT3-H fryer cannot be operated during power failures. DO NOT attempt to bypass safety
controls and manually start the fryer.
CLEANING AND MAINTENANCE
A CLEANING: Any item of equipment operates better and lasts longer when it is kept clean and properly maintained, and this fryer is no
exception. In order for the fryer to provide years of trouble-free service, it must be CLEANED and MAINTIANED according to instructions
contained herein and at the intervals listed below:
1. DAILY
a. FILTER shortening in each fryer vat after the LUNCH and DINNER rush and more often in high volume sale stores.
CAUTION: PRIOR TO CLEANING THE FRYER VAT, REMOVE THE 120 VOLT ELECTRICAL PLUG FROM THE
ELECTRICAL RECEPTACLE AND TURN THE MANUAL GAS VAVLE OFF.
b. Clean the fryer surface with a solution of hot water and detergent periodically during operating hours and with stainless steel cleaner
at closing. If necessary, use a dampened 3M type 7447 RED or 3M type 7440 heavy duty BROWN Scotchbrite pad to remove
encrusted material. DO NOT use steel wool, abrasive cloths, cleaners, powders, metal knife, spatula or any other metal object to
scrape stainless steel! Scratches on stainless steel are almost impossible to remove!
13
CAUTION: DO NOT ALLOW ANY CLEANING SOLUTION/WATER TO SPLASH INTO A VESSEL OF HOT COOKING
OIL AS IT WILL CONTAMINATE THE OIL AND MAY CAUSE THE OIL TO SPALTTER CAUSING SEVERE BURNS.
c. THOROUGHLY clean the lter machine according to instructions provided in the cleaning section of this manual.
2. WEEKLY
a. BOIL OUT the fryer vat using Boil Out Compound according to procedures in the cleaning manual provided by the chemical supplier
b. Perform steps 2) and 3) listed above under Daily Cleaning routines.
B MAINTENANCE - If the Model ZRT3-H gas fryer is equipped with an Ultrastat 11, 21, or 25 Cooking Computer NO maintenance is required
on the Temperature Sensing Probe. However, if the fryer is equipped with a Default-to-Manual-Restart (DTMR) Control, the Fenwal Temper-
ature Controller or Electronic Thermostat may need to be adjusted or calibrated according to the following procedure:
C. ELECTRONIC THERMOSTAT CALIBRATION - The Electronic Thermostat in all fryer congurations are equipped with a
Dial and Knob and should be checked and calibrated when necessary as follows:
1. ENSURE electrical power and, if applicable, gas to the fryer has been
turned OFF.
2. CAREFULLY drain sufcient shortening from the fryer to LOWER the
shortening about 4” (102 mm) beneath the Electronic Thermostat sensing
probe.
3. After the sensing probe has COOLED, loop the bead of an ACCURATE
digital test thermometer temperature probe around the sensing element;
then connect the probe to the thermometer.
4. Replace shortening drained in step B and ENSURE it is level with the short-
ening level mark on the rear of the vat; then turn the power and, if applicable,
gas to the fryer ON.
5. Set the KNOB of the Electronic Thermostat to the CENTER (300) of the dial
and periodically STIR the shortening
in a COUNTER-CLOCKWISE (CCW)
direction with a long handle skimmer to pull congealed shortening UPWARD
from the Cold Zone area.
6. When shortening has reached the set temperature and the RED indicator lamp on the fryer has turned OFF, allow the Electronic Thermo-
stat to cycle ON and OFF about ve (5) times to stablize the system.
7. After the shortening temperature has stablized, record the temperature reading of the TEST THERMOMETER immediately after the
RED indicator lamp and the fryer turns OFF.
8. CAREFULLY loosen the set screw on the Electronic Thermostat KNOB without turning the thermostat potentiometer,
set the thermostat knob
pointer to the temperature recorded by the test thermometer; then tighten the set screw on the thermostat knob taking care not to turn the
thermostat’s potentiometer.
9. Repeat steps 1 and 2 above, remove the test thermometer temperature probe from the Electronic Thermostat sensing element; then repeat
step D to return the fryer to normal operation.
14
PREVENTIVE MAINTENANCE Minimal maintenance is required on Model ZRT#-H gas fryers because of its design and the materials used in
manufacture. However, some preventive maintenance and inspection must be performed periodically to prevent break downs which could cur-
tail food sales. Any preventive maintenance or inspection should be accomplished with CAUTION while the fryer is in operation since HOT
liquid shortening could cause severe burns. If service or repair is required, all gas and electric power MUST BE TURNED OFF PRIOR TO
performing that service or repair.
PREVENTIVE MAINTENANCE SCHEDULE
INSPECTION ITEM INSPECTION
PRIORITY
INSPECTION
DESCRIPTION
Grease Filters DAILY
Clean grease lters in the exhaust
hood each evening and allow them to
dry overnight.
Drain Valve & Shortening
Return Levers WEEKLY
Determine that all levers are securely
attached and that they can be easily
opened and closed.
Temperature Sensing Probes WEEKLY
During Boil-Out of the fryer, inspect
the temperature and high limit sens-
ing probes for any visual damage.
ELECTRONIC THERMOSTAT
TROUBLESHOOTING
A GENERAL: The problems and possible solutions listed in the troubleshooting chart below are typical problems that are frequently encountered.
ONLY qualied repairmen are to use the troubleshooting chart to repair this fryer. In the event a main burner malfunction occurs, perform the
following checks PRIOR to contacting a repairman:
1. Ensure Gas Valves are in their proper position.
2. Check that the fryer electrical plug is connected to an electrical receptacle.
3. Ensure the applicable Circuit Breaker is in the ON position and that the fryer ON/OFF switch is in the ON position.
4. Ensure the applicable fryer control has been placed in the FULL ON mode.
5. Ensure the gas supply line quick-disconnect coupling is SEATED on the gas manifold tting.
6. Determine that the blower is operating.
B TROUBLESHOOTING CHART: Should a problem occur that cannot be corrected after performing the above CHECKS, contact an
authorized repairman and/or Ultrafryer Systems Systems Customer Service 1-800-525-8130 and provide the information acquired while
performing these checks.
CAUTION: ENSURE REPAIRMEN ARE ADVISED THAT FRYER RESTRAINTS MUST BE DISCONNECTED/CONNECTED.
IF A FRYER IS TO BE MOVED DURING MAINTENANCE OR REPAIR, AND THAT ELECTRICAL POWER AND GAS
MUST BE TURNED OFF PRIOR TO PERFORMING ANY MAINTENANCE OR REPAIR.
TROUBLESHOOTING CHART
ISSUE PROBLEMS POSSIBLE SOLUTIONS
1Main burner will not ignite. Blower is operating;
but gas is not present at the burner.
A. Check the Blower Motor air pressure Switch by temporarily discon-
necting the two (2) ORANGE blower motor wires and connecting
them together. If the IGNITOR sparks when these wires are con-
nected, the air pressure switch is defective and it will have to be
replaced.
B. Check the following components and replace if found to be
defective: Gas Control Valve
Hi-Limit Switch
Transformer
2Electrical power is present at the fryer, but the
Blower is not operating.
A. Blower Motor may have over-heated and shut off on thermal over-
load. If this situation did occur, it will correct itself when the mo-
tor cools (10-20 minutes). If this overheating problem persists, re-
place the blower motor.
3
Excessive time is required to raise the shortening to
cooking temperature. Temperature recovery is slow
and main burner ames are small and appear to be
lethargic.
A. Ensure that the MANUAL GAS VALVE is completely open.
B. Check for an obstruction in the gas line.
C. Check for an obstruction in the ue pipe.
D. Check that the ORFICE PLUG has the correct drill size opening as
indicated on the operational requirements on the chart shown on
page 3.
E. Check for damaged BLOWER MOTOR ns.
F. Use a standard water-type U-gauge Manometoer to check the pres-
sure at the gas control valve pressure tap. Proper gas pressure is
indicated on the operational requirementschart shown on page 3.
NOTE: If necessary remove the Pressure Regulator Adjustment Cover and
adjust this control to the proper pressure. (Turn adjusting screw CLOCK-
WISE to increase gas pressure to the burner and COUNTER CLOCKWISE
to decrease gas pressure. Replace adjustment cover.)
4Shortening temperature is too high and breaks down
quickly.
A. Check the gas pressure as described above.
B. Check calibration of the Fenwal Temperature or Electronic
Thermostat with an ACCURATE digital thermometer.
5
The lter pump motor fails to operate when the Vat
Shortening Return / Topside Shortening Lever is
placed in the OPEN position.
A. Insure the lter pump micro-switch is good, then check the manual
reset button on the lter pump motor.
B. If the lter pump motor fails to operate after the reset button has
been depressed, repair or replace the motor.
6 Decreased shortening ow rate while ltering.
A. Check for excessive sediment on the lter screen, standpipe suction
tting or in lter tub.
7
Pump/Motor operates but does not pump shoretening.
A. Check for congealed shortening in the shortening system.
B. Check for loose Standpipe / Suction Line Coupler connection.
8 Pump / Motor hums but will not pump shortening A. Check for congealed shortening in the pump or in shortening
plumbing.
15
RECOMMENDED SPARE PARTS: To minimize downtime on the Model ZRT3-H gas fryer upon failure of a component part, at least one (1)
of the following items should be kept as a spare part in the local area:
MODEL ZRT3-H GAS FRYER
RECOMMENDED SPARE PARTS LISTING
Description Manufacturer’s Part Number PN
Replacement Pump Motor Kit --- 12B129
Ignitor Spark Module Honeywell S87B1008 18-179
24 Volt Stepdown Transformer Honeywell AT40A1121 18-180
24 Volt Combination Gas Control Valve Honeywell VR8203A-1005 18-227
SPDT Toggle ON / OFF Switch --- 18A287
Air Pressure Switch SMD 1204 18A291
Hi-Limit Switch Model 103KM1 Stemco 103K 19A144
” (13mm) Apollo Pump Control Valve --- 24-036
” (5mm) Compression Fitting --- 24-247
” (13mm) Manual Gas Valve Glacomini R602 24-326
Type RV48L Gas Pressure Regulator --- 24A134
Fasco Blower Motor Kit --- 19A547
Blower Motor Gasket --- 19A548
TECHNICAL ASSISTANCE – Contact the local repairman, service agent or Ultrafryer Systems Customer Service Department at 1-800-525-8130
for technical assistance or to perform any maintenance or repair that may be necessary.
CLEANING - Any item of equipment operates better and lasts longer when it is kept clean and properly maintained. The Model ZRT3-H Gas Fryer is
no exception. In order for this fryer to provide years of trouble-free service, it must be CLEANED and MAINTAINED according to instructions
herein and at the intervals listed below:
A. DAILY
1. Clean the fryer surface periodically during operating hours with a solution of santizer and hot water, and at closing with stainless steel
cleaner. If necessary, use a dampened 3M type 7447 RED or 7440 BROWN (heavy duty) Scotch Brite pad to remove encrusted material.
DO NOT use steel wool, abrasive cloths, cleaners, powders or metal devices to scrape stainless steel! Scratches on stainless steel are
almost impossible to remove!
CAUTION: DO NOT ALLOW ANY CLEANING SOLUTION OR WATER TO SPLASH INTO A VESSEL OF HOT COOKING
OIL, AS IT WILL CONTAMINATE THE OIL AND MAY CAUSE THE OIL TO SPLATTER CAUSING SEVERE BURNS.
18” ZRT3-H GAS FRYER
16
14” ZRT3-H GAS FRYER
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