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Frymaster D80 Series manual

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Table of contents for the manual

  • Page 1

    Price: $10.00 *8195706* Service Hotline 1-318-865-1711 819-5706 JUNE 2002 Decathlon Series Gas Fryers (CE) Installation & Operation Manual D20, D50, D60 & D80 Series CE ONLY[...]

  • Page 2

    [...]

  • Page 3

    DANGER The front ledge of the fryer is not a step. Do not stand on the fryer. Serious injury can result from slips or contact with the hot oil. DANGER Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. DANGER Instructions to be followed in the event the operator smells gas or otherwise[...]

  • Page 4

    Decathlon Series Gas Fryers (CE) Installation & Operation Manual TABLE OF CONTENTS Page # 1. INTRODUCTION 1-1 1.1 Applicability and Validity 1-1 1.2 After Purchase 1-1 1.3 Ordering Parts 1-1 1.4 Service Information 1-2 1.5 Computer Information 1-2 1.6 Safety Information 1-2 1.7 Service Personnel 1-3 2. IMPORTANT INFORMATION 2-1 2.1 Receiving an[...]

  • Page 5

    Decathlon Series Gas Fryers (CE) Installation & Operation Manual TABLE OF CONTENTS (CONT.) Page # 4. FRYER OPERATIONS 4-1 4.1 Initial Start-up 4-1 4.2 Boil-Out Procedure 4-3 4.3 Final Preparation 4-5 5. THERMATRON OPERATION 5-1 5.1 Operating Fryers with Thermatron Controllers 5-1 6. PREVENTATIVE MAINTENANCE 6-1 6.1 General 6- 1 7. TROUBLESHOOTI[...]

  • Page 6

    FINDING YOUR WAY AROUND THE DEAN DECATHLON 3” Round Drains (SCFD models) 1.5” Round Drains To p C a p Flue Cap Basket Hanger Frypot Drain Tubes Drain Valve Handle (Red ) Oil Return Han dle (Y ellow) Drain Flush Handle (Blu e) Filter Unit Electronic Operating Thermostat Drain Tubes Burners A[...]

  • Page 7

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 1: INTRODUCTION 1 - 1 1.1 Applicability and Validity The Dean Decathlon Series gas model family has been approved by the European Union (EU) for sale and installation in the following EU countries: AT, BE, KE, KD, ES, FI, FR, GB, IE, IT, LU, NL, NO, PT and SE. This manual is applicable to and valid for all D[...]

  • Page 8

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 1: INTRODUCTION 1 - 2 1.4 Service Information Call the Dean Service Hotline, 1 - 800 - 551 - 8633, for the location of your nearest factory authorized service center. To assist y ou more efficiently, always provide the service technician with the model number, gas type, serial number, and the nature of the p[...]

  • Page 9

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 1: INTRODUCTION 1 - 3 1.6 Safety Information (cont.) WARNING boxes contain information about actions or conditions that may cause or result in damage to your system , an d which may cause your system to malfunction. WARNING Example of a WARNING box. DANGER boxes contain information about actions or condition[...]

  • Page 10

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 2: IMPORTANT INFORMATION 2 - 1 2.1 Receiving and Unpacking Equipment A. Check that the container is upright. Use an outward prying motion - no hammering - to remove the carton. Unpack the fryer carefully and remove all accessories from the carton. Do not discard or misplace these, as th ey will be needed. B.[...]

  • Page 11

    DECATH LON SERIES GAS FRYERS (CE) CHAPTER 2: IMPORTANT INFORMATION 2 - 2 2.2 General (cont.) Where conflicts exist between instructions and informatio n in this manual and local code or national codes, or regulations, installation and operation shall comply with the codes or regulations in force in the country in which the equipment is installed. C[...]

  • Page 12

    DECATH LON SERIES GAS FRYERS (CE) CHAPTER 2: IMPORTANT INFORMATION 2 - 3 2.4 Rating Plate This is attached to the inside right - hand corner of the front door panel. Information provided includes the model and serial number of the fryer, kW/hr (BTU/hr) of the burners, outlet gas pressure in mbars (inche s W.C.) and whether the unit has natural or p[...]

  • Page 13

    DECATH LON SERIES GAS FRYERS (CE) CHAPTER 2: IMPORTANT INFORMATION 2 - 4 2.5 Pre - Installation (cont.) 3. Combustible construction with a minimum clearance of 15 - cm (6 - inch) side and 15 - cm (6 - inch) rear, and equipped with factory - supplied 15 - cm (6 - in ch) adjustable legs or 13 - cm (5 - inch) casters. DANGER Local building codes prohi[...]

  • Page 14

    DECATH LON SERIES GAS FRYERS (CE) CHAPTER 2: IMPORTANT INFORMATION 2 - 5 2.6 Air Supply and Ventilation (cont.) F. Adeq uate distance must be maintained from the flue outlet of the fryer(s) to the lower edge of the filter bank. Per NFPA Standards No. 96, a minimum of 45 - cm (18 - inches) should be maintained between the flue(s) and the lower edge [...]

  • Page 15

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 3: INSTALLATION 3 - 1 3.1 Installing the Fr yer A. Initial Installation : If the fryer is installed with legs, do not push the fryer to adjust its position. Use a pallet or lift jack to lift the fryer slightly, then place the fryer where it is to be installed. B. Relocating the fryer : Rem ove all weight fro[...]

  • Page 16

    DECATHLON SERIE S GAS FRYERS (CE) CHAPTER 3: INSTALLATION 3 - 2 3.3 Installing Casters and Legs A. Install casters and/or legs near where the fryer is to be used, as neither is secure for long transit. Decathlon Series (CE) gas fryers cannot be curb mounted and must be equipped with either legs or casters provided. B. Aft er unpacking, use a pallet[...]

  • Page 17

    DECATHLON SERIE S GAS FRYERS (CE) CHAPTER 3: INSTALLATION 3 - 3 3.4 Gas Categories Installation shall be made with a gas connector that complies with national and local codes. Quick disconnect devices, if used, shall likewise comply with national and local codes. WARNING The fryer MUST be connected to the gas supply specified on the rating and seri[...]

  • Page 18

    DECATHLON SERIE S GAS FRYERS (CE) CHAPTER 3: INSTALLATION 3 - 4 3.5 Gas Connections DANGER Before connecting new pipe to this appliance the pipe must be blown out thoroughly to remove all foreign material. Foreign material in the burner and gas controls will cause improper and dangerous op eration. A. The gas supply (service) line must be the same [...]

  • Page 19

    DECATHLON SERIE S GAS FRYERS (CE) CHAPTER 3: INSTALLATION 3 - 5 3.5 Gas Connections (cont.) C. Manual shut - off valve : This gas service supplier - installed valve must be installed in the gas service line ahead of the fryers in the gas stream and in a position where it can be reached quickly in the event of an emergency. D. Regulating Gas Pressur[...]

  • Page 20

    DECATHLON SERIE S GAS FRYERS (CE) CHAPTER 3: INSTALLATION 3 - 6 3.5 Gas Connections (cont.) H. Orifices : The fryer can be configured to operate on any available gas. The correct safety control valve, appropriate gas orifices, and pilot burner are installed at the factory. Whil e the valve can be adjusted in the field, only qualified service person[...]

  • Page 21

    DECATHLON SERIE S GAS FRYERS (CE) CHAPTER 3: INSTALLATION 3 - 7 3.5 Gas Connections (co nt.) 4. To limit movement of the fryer, restraints independent of the flexible coupling or connector must be used. Clips are located on the back panel of the fryer for the attachment of restraints. 5. If disconnection of the restraint is necessary, the restra in[...]

  • Page 22

    DECATHLON SERIE S GAS FRYERS (CE) CHAPTER 3: INSTALLATION 3 - 8 3.6.1 CE Specifications 3.6.1.1 Gas Types and Specifications MODEL* NOMINAL HEAT INPUT - Qn (kW) GAS TYPE ORIFICE SIZE (MM)† ORIFICE PART NO. ORIFICE QTY/ COLOR D 80 G 37,5 G20 G25 G31 2,40 2,40 1,51 810 - 2060 810 - 2060 810 - 2059 5 /BLUE 5/BLUE 5/RED D 60 G 37,5 G20 G25 G31 2,40 2[...]

  • Page 23

    DECATHLON SERIE S GAS FRYERS (CE) CHAPTER 3: INSTALLATION 3 - 9 3.6.1.2 Adjustments to Different Gas Types (cont.) NOTE: Outlet gas pressure must be adjusted strictly within the above requirements 5 to 10 minutes after the appliance is operating. * For controls and adjustments, please refer to "gas valve" illustration on page 3 - 10. (Pil[...]

  • Page 24

    DECATHLON SERIE S GAS FRYERS (CE) CHAPTER 3: INSTALLATION 3 - 10 3.6.2 Gas Conversion Procedures (cont.) When converting from G20 (20 mbar) to G25 (25 mbar), or vice - versa, or G31 (37 mbar) to G31 (50 mbar), the following procedures apply: ? ? C heck pilot - adjustment and adjust as necessary. ? ? Other adjustments are not necessary. Conversion f[...]

  • Page 25

    DECATHLON SERIE S GAS FRYERS (CE) CHAPTER 3: INSTALLATION 3 - 11 3.7 Electrical Connections The fryer when installed must be electrically grounded in accordance with local codes, or in the absence of local codes, with the appropriate national or European Community (CE) standards. DANGER This fryer is equipped with a three - prong (grounding) plug f[...]

  • Page 26

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 4: FRYER OPERATIONS 4 - 1 4.1 Initial Start - up WARNING The on - site supervisor is responsible for ensuring that operators are made aware of the inherent hazards of operating a hot oil frying system, particularly the aspects of system operation, oil filtration, draining and clean ing procedures. Cleaning :[...]

  • Page 27

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 4: FRYER OPERATIONS 4 - 2 4.1.1 Pilot Lighting Procedures Initial Pilot Lighting : All Dean fryers are tested, adjusted and calibrated to sea level conditions before leaving the factory. Adjustments to assure proper operation of pilot may be necessary on installation to meet local conditions, low gas pressur[...]

  • Page 28

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 4: FRYER OPERATIONS 4 - 3 4.1.2 Pilot Lighting Procedures, Electronic Ignition Systems WARNING Never use a match or taper to light pilot on this ignition system. 1. Turn gas "ON". 2. Turn electric power "ON" with the approp riate rocker switch or controller/computer. 3. The ignition modul[...]

  • Page 29

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 4: FRYER OPERATIONS 4 - 4 4.2 Boil - Out Procedure (cont.) A. Pour cleaning solution into the frypot and add water to the bottom OIL LEVEL line scribed in the back of the frypot. B. Operating th ermostat - equipped fryers: Set dial/temperature controller to 107ºC (225°F), just above that of boiling water. [...]

  • Page 30

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 4: FRYER OPERATIONS 4 - 5 4.2 Boil - Out Procedure (cont.) J. Close the d rain, add fresh water (without boil - out solution) and wash all surfaces of the frypot. Drain again. K. Refill the frypot with fresh water and vinegar to neutralize any residual boil - out solution. Wash all surfaces of the frypot. Dr[...]

  • Page 31

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 4: FRYER OPERATIONS 4 - 6 4.3.1 Filling Fryer with Cooking Oil/Shortening (cont.) D. Operating Thermostat : Turn the burners "ON" for about 10 seconds, "OFF" for a minute, etc., until the sh ortening is melted. If you see smoke coming from the shortening while melting this way, shorten th[...]

  • Page 32

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 5: THERMATRON OPERATION 5 - 1 5.1 Operating Fryers with Thermatron Controllers Many Decathlon fryers use a solid - state temperature controller, or Thermatron ® controller instead of a computer or basic thermostat. A Thermatron system incorporates a temperature - control circuit board, a potentiometer, and [...]

  • Page 33

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 5: THERMATRON OPERATION 5–2 5.1 Operating Fryers with Thermatron Controllers (cont.) MAIN POWER SWITCH – connects/disconnects primary power; double - lighted with center position "OFF". One main switch controls two Thermatron controllers/Compu - Fry computers and/or two back - up thermostats. W[...]

  • Page 34

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 5: THERMATRON OPERATION 5–3 5.1 Operating Fryers with Thermatron Controllers (cont.) Configuration #2 Manual Filter Power Switch (if equipped with filter system) : Connects/disconnects power to filter pump if primary system fails. Fryer power switch should be "OFF" when filter is in use. F BOIL O[...]

  • Page 35

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 6: PREVENTATIVE MAINTENANCE 6 - 1 6.1 General DANGER Never attempt to clean the fryer during the cooking process or when the frypot is filled with hot oil/shortening. If water comes in contact with oil/shortening heated to cooking temperature, it will cause spattering of the oil/shor tening, which can result[...]

  • Page 36

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 6: PREVENTATIVE MAINTENANCE 6 - 2 6.1.3 Periodic/Annual This appliance should be inspected and adjusted periodically by qualified service personnel as part of a regular kitchen maintena nce program. Frymaster/Dean recommends that this appliance be inspected at least annually by a Factory Authorized Service T[...]

  • Page 37

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 7: TROUBLESHOOTING 7 - 1 7.1 General DANGER Hot cooking oil/shortening will cause severe burns. Never attempt to move this appliance when filled with hot cooking oil/shortening or to transfer hot cooking oil/shortening from one container to another. DANGER This equipment s hould be unplugged when servicing, [...]

  • Page 38

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 7: TROUBL ESHOOTING 7 - 2 7.2 Pilot Burner Malfunction (cont.) 4. Check all connections for cleanliness and security. C. Pilot flame of proper size, but is unsta ble. Flame wavers and does not envelop the thermocouple completely at all times. 1. Check for drafts that might be caused by air conditioning equip[...]

  • Page 39

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 7: TROUBL ESHOOTING 7 - 3 7.3 Main Burner Malfunctions (cont.) D. Fryer will not reach the temperature setting and/or runs erratically. 1. Incorrect location of sensor probe or defective temperature sensor. 2. Loose wiring/wire connection E. Fryer shortening temperature cannot be controlle d; fryer runs at h[...]

  • Page 40

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 7: TROUBL ESHOOTING 7 - 4 7.5 Wiring Diagrams 7.5.1 Decathlon D - 50G and D - 60G - Thermatron Con trols - CE Only 1 2 3 4 5 6 7 8 9 3 4 1 2 2 1 4 3 1 3 7 8 9 2 6 2 1 4 3 5 7 8 9 6 2 1 4 3 5 6 2 1 4 3 5 Temperature Sensor POT 220 VAC POWER SUPPLY FUSE 2 AMP POWERSWITCH 230 VAC 24 VAC 48 OHM RESISTOR 24V &quo[...]

  • Page 41

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 7: TROUBL ESHOOTING 7 - 5 7.5.2 Decathlon D - 50G and D - 60G - Computer - CE Only 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 1 2 5 3 4 6 7 8 9 FUSE FUSE 240V 24V 240V 12V C NO NC 1 2 1 2 9 2 1 3 4 5 6 7 8 11 10 12 14 13 15 3 2 1 7 6 5 4 9 10 8 14 13 11 12 15 COMPUTER INTERFACE B[...]

  • Page 42

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 7: TROUBL ESHOOTING 7 - 6 7.5.3 UFF Filtration - Typical Wiring CIRCUIT BREAKER 5 AMP- 230V P/N 807-3538 T3 P2 T8 HEAT TAPE - 25 WATT P/N 810-2100 MOTOR COVER PLATE P/N 807-3643 FUSE HOLDER P/N 807-1321 FUSE P/N 807-3592 LOW VOLTAGE SHOWN BLK WHT#1 JUCTION BOX P/N 807-3642 P1 BLK J BOX P1 HIGH VOLTAGE SHOWN [...]

  • Page 43

    DECATHLON SERIES GAS FRYERS (CE) CHAPTER 7: TROUBL ESHOOTING 7 - 7 7.6 Recommended Spare Parts Commonly replaced parts in older Decathlon Series gas fryers are: Gas Valve - G20/G25 (CE) - 807 - 2091 Gas Valve - G31 (CE) - 807 - 2127 High - Limit Thermostat - 807 - 3560 Thermocouple - 810 - 1152 Temperature Sensor Probe, Thermatron (D20, D50) - 106 [...]

  • Page 44

    Dean, 8700 Line Avenue, PO Box 51000, Shreveport, Louisiana 71135 - 1000 Shipping Address: 8700 Line Avenue, Shreveport, Louisiana 71106 TEL 1 - 318 - 865 - 1711 FAX (Parts) 1 - 310 - 327 - 3343 FAX (Tech Support) 1 - 318 - 219 - 7135 Price: $10.00 PRINTED IN THE UNIT ED STATES SERVICE HOTLINE 1 - 800 - 551 - 8633 819 - 5706 JUNE 2002[...]