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Frymaster HD manual

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Table of contents for the manual

  • Page 1

    NON-CE & Dean, a member of the C ommercial Food Equipm ent Service Associati o n, recomm ends using CFESA Certified Technicians. 24-Hour Service Hotline 1-800-551-8633 MAY 2007 PRINTED IN THE UNITED STATES OF AMERICA *8195698* Decathlon Series Gas Fryers (D & HD Models) Installation & Operation Manual Please read all sections of this ma[...]

  • Page 2

    NOTICE This appliance is intended for professional use only and is to be operated by qualified personnel only. A Frymaster and Dean Factory Authorized Service Center (FASC) or other qualified professional should perform installation, maintenance, and repairs. Installation, maintenance, or repairs by unqualified personnel may void the manufacturer?[...]

  • Page 3

    DANGER Adequate means must be provided to limit the movement of this appliance without depending upon the gas line connection. Single fryers equipped with legs must be stabilized by installing anchor straps. All fryers equipped with casters must be stabilized by installing restraining chains. If a flexible gas line is used, an additional restrainin[...]

  • Page 4

    High Efficiency Decathlon (HD) Series Gas Fry ers Installation & Operation Manual TABLE OF CONTENTS 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 1-3 1.7 Service Personnel 1-3 2. IMPORTANT INFORMATION 2-1 2.1 Re[...]

  • Page 5

    High Efficiency Decathlon (HD) Series Gas Fry ers 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. CONTROLLER OPER ATING INSTRUCTI ONS 5-1 5.1 Operating Instructions: El ectronic Thermostat C ontroller 5-1 5.2 Electronic Ther[...]

  • Page 6

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 1: INTRODUCTION 1-1 1.1 Applicability and Validity The Dean Decathlon Series gas model family (D models) has been approved by the European Union (EU) for sale and installation in the follow ing EU countries: AT, BE, KE, KD, ES, FI, FR, GB, IE, IT, LU, NL, NO, PT and SE. The Dean High Efficien[...]

  • Page 7

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 1: INTRODUCTION 1-2 1.4 Service Information Call the Dean Service Hotline, 1-800-551-863 3, for th e location of your nearest factory au thorized service center. To assist you more efficiently, always provide the se rvice technician with the model number, gas type, seri al number, and the na [...]

  • Page 8

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 1: INTRODUCTION 1-3 1.7 Service Personnel A. Qualified and/or Authorized Operating Pers onnel 1. Qualified/authorized operating pe rsonnel are those who have car efully read the info rmation in this manual and have familiarized them selves with the equipm ent functions, or have had previous e[...]

  • Page 9

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2-1 2.1 Receiving and Unpacking Equipment A. Check that the container is uprigh t. Use an outward prying m otion - no hammering - to remove the carton. Unpack the fryer carefully and rem ove all accessories from the carton. Do not discard or misplace these, as they wi[...]

  • Page 10

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2-2 2.2 General (cont.) Where conflicts exist between instructions and in formation in this manual and local code or national codes, or regulations , installation and operation sh all comply w ith the codes or regulations in force in the country in which the equipment[...]

  • Page 11

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2-3 2.5 Rating Plate This is attached to the inside front door panel. Information provided includes the model and serial number of the fryer, BTU/hr input of the burners, outlet gas pressure in inches W.C. and whether the unit has natural or propane gas orifices. DANG[...]

  • Page 12

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2-4 2.6 Pre-installation (cont.) C. Installation Standards 1. U.S. installations must meet : 2. Canadian inst allations m ust meet : American National Standard Instit ute CAN 1-B149 Installation Codes ANSI Z83.11 Canadian Gas Association American Gas Association 55 Sc[...]

  • Page 13

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2-5 2.7 Air Supply and Ventilation (cont.) D. Do not place the fryer’s flue outlet directly into the plenum of the hood, as it will affect the gas combustion of the fryer. E. Never use the interior of the fr yer cabinet for storage or st ore items on shelving over o[...]

  • Page 14

    DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3-1 3.1 Installing the Fryer NOTE: HD Series fryers have not been approved for use in the European Union (EU) and cannot be sold or installed in EU countries. Only D Series fryers have been approved for sale and installation in EU countrie s. A. Initial Installation: If the fryer is i[...]

  • Page 15

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS 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 gas fryers cannot be curb-mounted and m ust be equipped with either l egs or cas ters provide d. B. After unpacking, u[...]

  • Page 16

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3-3 3.4 Gas Connections DANGER Before connecting new pipe to this appliance the pipe must be blown out thoroughly to remove all foreign material. Foreign mate rial in the burner a nd gas controls will cause improper and dangerous operation. U.S. NATIONAL CODE REQUIREMENTS This[...]

  • Page 17

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3-4 3.4 Gas Connections (cont.) Gas Supply Type and Pressure Gas Supply Type Gas Supply Pressure Natural Gas 6-10" W.C. (Dynamic) Propane (LP) Gas 11-13" W.C. (Dynamic) DANGER When pressure-testing incoming gas supply lines, disconnect the fryer from the gas line if [...]

  • Page 18

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3-5 3.4 Gas Connections (cont.) DANGER When pressure-testing incoming gas supply lines, disconnect the fryer from the gas line if the test pressure is ½" PSI [3.45 kPa (14 inches W.C.)] or greater to avoid damage to the fryer’s gas piping and gas valve(s). D. Manifold [...]

  • Page 19

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3-6 3.5 Gas Connections (cont.) WARNING Do not attach accessories to this fryer unl ess fry er is secured from tipping. Personal injury may result. 2. The fryer must be restrained by means independent of the flexible coupling or connector in order to limit the movem ent of the[...]

  • Page 20

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3-7 3.5 Gas Specifications CE ONLY ( Altitudes of 2000 feet or less ) EQUIPMENT PRESSURE MODEL INPUT (kW) GA S TYPE ORIFICE (MM) ORIFICE PART NO . QTY MBAR INCH W. C . D20G 15,0 G20 G25 G31 2,40 2,40 1,51 810-2060 810-2060 810-2059 2 2 2 10,0 15,0 27,0 4,0 6,0 10,8 D50G 30,0 G[...]

  • Page 21

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3-8 3.7 Electrical Connections The fryer when installed must be electrically gr ounded in accordan ce with lo cal codes, or in the absence of local codes, with the National Electrical Code, ANSI/N FPA 70-(latest ed ition). DANGER This fryer is equipped with a three-pr ong (gro[...]

  • Page 22

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

  • Page 23

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4-2 4.1.1 Pilot Lighting Proce dures, Standing Pilot Only Initial Pilot Lighting : All Dean fryers are tested, adjusted a nd calibrated to sea level conditions before leaving the factory. Adjustments to assure prope r operation of pilot may be necessary on i nstallation to[...]

  • Page 24

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

  • Page 25

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4-4 4.2 Boil-Out Procedure (cont.) A. Pour cleaning solution into the fr ypot and add water to the bottom OIL LEVEL line scribed in the back of the frypot. B. Operating thermostat-equipped fr yers: Set dial/temperature cont roller to 225°F (107ºC), just above that of boi[...]

  • Page 26

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4-5 4.2 Boil-Out Procedure (cont.) J. Close the drain, add fresh wate r (without boil-out solution) a nd wash all surfaces of the frypot. Drain again. K. Refill the frypot with fresh wate r and vinegar to neutralize any residual boil-out solution. Wash all surfaces of the [...]

  • Page 27

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4-6 4.3 Final Preparation (cont.) D. Operating Thermo stat : Turn the burners "ON" for about 10 seconds, "OFF" for a minute, etc., until the shortening is melted. If you see smoke coming from the shortening while melting this way, shorten the "ON&q[...]

  • Page 28

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 5: CONTROLLER OPERATING INSTRUCTIONS 5–1 5.1 Operating Instructions: Electronic Thermostat Controller Decathlon Series gas fryers come standard with an electronic thermostat controller, w hich incorporates a temperature-contro l circuit boar d, a potentiom eter, and a temperature probe. The[...]

  • Page 29

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 5: CONTROLLER OPERATING INSTRUCTIONS 5–2 5.1 Operating Instructions: Electronic Thermostat Controller (cont.) FRYER POWER SWITCH – This switch turns the fryer on and off. Wh en the power switch is in the "ON" position, the indicator light will be lit w h en calling for heat. BOI[...]

  • Page 30

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 5: CONTROLLER OPERATING INSTRUCTIONS 5–3 5.2 Electronic Thermostat Controller/Computer (cont.) MAIN POWER SWITCH – connects/disconnects primary pow er; double-lighted with center position "OFF". One main switch controls two electronic ther mostats/Compu-Fry or remote computers. [...]

  • Page 31

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 6: FILTRATION 6-1 WARNING Drawings and photos used in this manual are intended to illu strate operational, cleaning and technical procedures and ma y not conform to on-site management operational procedures. 6.1 General Most SUFF/UFF systems use filter paper as the f ilter medium. Som e filte[...]

  • Page 32

    SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6-2 6.2 Filter Preparation On initial installation and before each use, clean the filter: a. remove all loose parts from the filter, b. wash the filter pan and all ac cessories in hot, soapy water, c. and dry thoroughly. 6.2.1 Filter Unit Types FILTER PAPER AND HOLD DOWN RING Filter [...]

  • Page 33

    SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6-3 6.2.1 Filter Unit Types (cont.) FILTER LEAF A filter leaf is a fine mesh screen which is reus able and takes the p lace of disposable paper. Oil moves through the leaf, leaving behi nd impurities. 1. Filter pan. 2. Filter leaf. 3. Crumb Screen. 4. Filter pan lid. 5. Caster. 4 3 2[...]

  • Page 34

    SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6-4 6.2.2 Assembling the Filter FILTER PAPER AND HOLD DOWN RING 1. Place the support grid in the bottom of filter pan. 2. Put one filter paper sheet on top of the support grid. Be sure the paper covers the filter pan bottom and laps two inches onto the pan wall. 3. Position the hold-[...]

  • Page 35

    SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6-5 6.2.2 Assembling the Filter (cont.) 4. Sprinkle 8 ounces (227g) of filter powder on the filter sheet. Ensure the powder covers the filter paper evenly. 5. Place the crumb screen in the filte r pan. Allow the crumb screen to rest on the top edges of the hold-down ring. 6. Place fi[...]

  • Page 36

    SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6-6 6.2.2 Assembling the Filter (cont.) FILTER LEAF 1. Remove the filter pan from the fryer by pulling out on the filter pan handle. 2. Remove the filter pan lid picking it up off of the pan. 3. Remove the crumb basket by lifting it up and out of the filter pan. Be careful not to dam[...]

  • Page 37

    SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6-7 6.2.2 Assembling the Filter (cont.) 7. Sprinkle 8 ounces (227g) of filter powder on the filter leaf. Ensure the powder covers the mesh evenly. 8. Replace the crumb tray in the pan af ter filter powder application. 9. Replace the pan lid. Ensure the pick up tube is properly positi[...]

  • Page 38

    SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6-8 6.2.3 Installing the Filter 10. Slide the filter inside the frye r cabinet. Ensure the male-femal e pickup tubes are fully engaged. Ensure the filter pan opening is di rectly under the center dump tube. 6.3 Daily Filter Operation WARNING Use caution and wear proper protect ive cl[...]

  • Page 39

    SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6-9 6.3.2 Filtering Tools Assemble tools to be used for filtering. These ar e supplied with the filter starter kit included with the fryer/filter system: • Frypot/Filter Brush - used to cl ean frypot and filter pan sides and bottom, heating elements, and to dislodge sediment dur in[...]

  • Page 40

    SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6-10 6.4 Operating the Filter 6.4.1 Pan Preparation and Operation See Section 6.2.1, Assembling the Filter , and Section 6.2.2, Installing the Filter , for the appropriate filter preparation procedure. For opti onal filter hose and wand, see Section 6.4.3, Optional Filter Hose and Wa[...]

  • Page 41

    SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6-11 6.4.1 Pan Preparation and Operation (cont.) 4. After ensuring the filter pan is correctly positioned under the drain tubes, move the red handle to the ope n position (right) to drain the frypot into the filter pan. Drain ONLY one frypot at a time. The filter pan is designed to h[...]

  • Page 42

    SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6-12 6.4.2 Filter Operation 6. Oil will begin to pump from the f ilter pan into the frypot. If the frypot tubes, sides and bottom have sediment deposits, clean the frypot with the cleaning brush included with the fryer. Clean beneath and under the burner tubes, using care not to dist[...]

  • Page 43

    SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6-13 6.4.2 Filter Operation (cont.) 9. After all oil is pumped back into the frypot, bubbles will form, indica ting air in the oil return lines. Allow the oil to bubble for 10- 15 seconds to ensure all oil is evacuated from the return line s. Push the yellow handle to close the oil r[...]

  • Page 44

    DECATHLON SERIES GAS FRYERS CHAPTER 5: UNDER FRYER FILTER (SUFF/UFF) FILTRATION 6-14 6.4.2 Filter Operation (cont.) 12. Do not allow crumbs to accum ulate in the crumb tray. The crumb tray MUST be emptied into a fireproof container at the end of frying operations EACH DAY (see DANGER statement below). DANGER The crumb tray in fryers equipped with a[...]

  • Page 45

    SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6-15 6.4.3 Optional Filter Hose and Wand Operation Some frying systems com e equipped with an op tional filter hose, wand, and toggle switch to facilitate the removal of debris from the frypot. The hose attaches to a no quick-disconnect on the bottom front of the fryer and is control[...]

  • Page 46

    SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6-16 6.4.3 Hose and Wand Operation (cont.) 4. The oil will start to flow imm ediately into the frypot. Keep the wand inside the frypot at all times while the filter pump is activated. 5. Rinse debris from the frypot into the filter pan with the wand. When cleanup is complete, close t[...]

  • Page 47

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 7: PREVENTATIVE MAINTENANCE 7-1 DANGER Never attempt to clean the fryer during th e 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 spatteri ng of the o il/shortening, which can re[...]

  • Page 48

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 7: PREVENTATIVE MAINTENANCE 7-2 7.3 Periodic/ Annual The fryer should be inspected and adjusted peri odically by qualified service personnel as par t of a regular kitchen maintenance program. Dean recommends that the fryer be inspected at le ast annually by a Factory Authorized Service Techni[...]

  • Page 49

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 8: TROUBLESHOOTING 8-1 DANGER Hot shortening will cause severe burns. Never attempt to move th is appliance when filled with hot shortening or to transfer hot shortening from one container to another. DANGER This equipment should be unplugged when ser vicing, except when electrical circuit te[...]

  • Page 50

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 8: TROUBLESHOOTING 8-2 8.1 Pilot Burner Malfunction (cont.) C. Pilot flame of proper size, but is unstable. Flame wavers and d oes not envelope the thermocouple completely at all tim es.  Check for drafts that might be caused by air conditioning equipment or m ake-up air apparatus. Turn ai[...]

  • Page 51

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 8: TROUBLESHOOTING 8-3 8.2 Main Burner Malfunctions (cont.) D. Fryer will not reach the temperatur e setting and/or runs erratically. 1. Incorrect location of sensor probe or defective temperature sensor. 2. Loose wiring/wire connection. E. Fryer shortening temperature ca nnot be controlled; [...]

  • Page 52

    Dean, 8700 Line Avenue, PO Box 5100 0, Shreveport, Louisiana 71135-1000 Shipping Address: 8700 Line Av enue, Shreveport, Louisiana 71106 TEL 1-318-865-1711 FAX (Parts) 1-31 8-688 -2200 FAX (Tech Support) 1-318-219-7135 PRINTED IN THE UNITED STATES SERVICE HOTLINE 1-800-551-8633 819-569 8 MAY 2007[...]