Frymaster D50G Installation Manual

Decathlon Series Gas Fryers

Installation, Operation & Maintenance Manual

D20, D50, D60 & D80 Series

Dean, a member of the Commercial Food Equipment Service Association, recommends using CFESA Certified Technicians.

24-Hour Service Hotline 1-800-551-8633

Price: $8.00

819-5698

10-00

Please read all sections of this manual and retain for future

reference.

This product has been certified as commercial cooking equipment and MUST be

installed by professional personnel as specified. Installation, maintenance and repairs

should be performed by your DEAN FACTORY AUTHORIZED SERVICE CENTER.

CAUTION

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this

or any other cooking appliance.

CAUTION

Instructions explaining procedures to be followed MUST be posted in a prominent

location in the event the operator detects a gas leak. This information can be obtained

from the local gas company or gas supplier.

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.

WARNING

Safe and satisfactory operation of your equipment depends on proper installation.

Installation MUST conform with local codes, or in absence of local codes, with the

National Fuel Gas Code, ANSI Z223.1; The Natural Gas Installation Code, CAN/CGA-

B149.1; or The Propane Installation Code, CAN/CGA-B149.2.

CAUTION

The crumb tray in fryers equipped with a filter system must be emptied into a fireproof

container at the end of frying operations each day. Some food particles can

spontaneously combust if left soaking in certain shortening material. Additional

information can be obtained in the filtration manual included with the system.

WARNING

SAFE AND SATISFACTORY OPERATION OF YOUR EQUIPMENT DEPENDS ON ITS

PROPER INSTALLATION. INSTALLATION MUST CONFORM TO LOCAL CODES, OR IN

THE ABSENCE OF LOCAL CODES, WITH THE LATEST EDITION OF THE NATIONAL

ELECTRIC CODE, N.F.P.A. 70.

Decathlon Series Gas Fryers

TABLE OF CONTENTS

Page #

1. INTRODUCTION 1-1

2. IMPORTANT INFORMATION 2-1

3. INSTALLATION INSTRUCTIONS 3-1

4. FRYER OPERATIONS 4-1

5. COMPU-FRY/THERMATRON INSTRUCTIONS 5-1

6. PREVENTATIVE MAINTENANCE 6-1

7. TROUBLESHOOTING 7-1

8. PARTS LIST 8-1

DECATHLON SERIES GAS FRYERS

CHAPTER 1: INTRODUCTION

1.1 After Purchase:

In order to improve service, have the following chart filled in by the Dean Authorized Service Technician who installed this equipment.

Authorized Service Technician/FASC Address

Telephone/Fax Model Number Serial Number Gas Type

1.2 Ordering Parts:

Customers may order parts directly from their local factory authorized service center. For this address and phone number, contact your factory authorized service center or call the Dean Industries Service Hotline phone number, 1-800-551-8633.

To speed up your order, provide the model number, serial number, gas type, part needed, item part number (if known), and quantity needed.

1.3 Service Information:

Call the Dean Service Hotline, 1-800-551-8633, for the location of your nearest factory authorized service center. To assist you more efficiently, always provide the service technician with the model number, gas type, serial number, and the nature of the problem.

1.4 Safety Information

Before attempting to operate your unit, read the instructions in this manual thoroughly.

Throughout this manual, you will find notations enclosed in double-bordered boxes similar to the ones below.

CAUTION boxes contain information about actions or conditions that may cause or result in a malfunction of your system.

1-1

CAUTION

Example of a CAUTION box.

WARNING boxes contain information about actions or conditions that may cause or result in damage to your system, and which may cause your system to malfunction.

WARNING

Example of a WARNING box.

DANGER boxes contain information about actions or conditions that may cause or result in injury to personnel, and which may cause damage to your system and/or cause your system to malfunction.

DANGER

Hot cooking oil causes severe burns. Never attempt to move a fryer containing hot cooking oil

or to transfer hot cooking oil from one container to another.

1-2

DECATHLON SERIES GAS FRYERS

CHAPTER 2: IMPORTANT INFORMATION

2.1 Product Description

The Dean Industries Decathlon Fryers are energy-efficient, tube-style, gas-fired units, design-certified by the International Approval Services (AGA/CGA), National Sanitation Foundation (NSF), and manufactured to their basic performance and application specifications.

All units are shipped completely assembled with accessories packed inside the fryer vessel. All units are adjusted, tested and inspected at the factory before shipment. Sizes, weights and input rates of all models are listed in this manual.

NOTE: The on-site supervisor is responsible for ensuring that operators are made aware of inherent

dangers of operating a deep fat fryer, particularly aspects of oil filtration, draining, and cleaning of the fryer.

2.2 Principles of Operation

The incoming gas flows through orifices and is mixed with air in the burners to create the correct ratio for proper combustion. The mixture is ignited at the front end of each heat tube by the pilot light. Internal diffusers slow the flame as it goes through the burner tube. This slower and more turbulent flame gives much better heat transfer to the walls of the tubes, thereby heating the oil better.

2.3 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, BTU/hr input of the burners, outlet gas pressure in inches WC and whether the unit has natural or propane gas orifices.

DANGER

Fryers MUST be connected ONLY to the gas type identified on the attached rating

plate.

2.4 Pre-Installation

A. General: Only a licensed gas fitter should install any gas-fired equipment.

1. A manual gas shut-off valve must be installed in the gas supply line ahead of the fryers for

safety and ease of future service.

2-1

2. The Dean Decathlon gas fryers require 120 VAC 60 cycle or 230VAC single-phase 50-hertz

(International/CE) electrical service and are equipped with a 16-3 SJT grounded flexible power cord for a direct connection to the power supply. Amperage draw for each unit depends on the accessories supplied with the unit. See detailed instructions packaged with the fryer.

B. Clearances: The fryer area must be kept free and clear of all combustibles. This unit is design-

certified for the following installations:

1. Commercial installation only (not for household use).

2. Non-combustible floor installation equipped with factory-supplied 6-inch (15-cm) adjustable

legs or 5-inch (13-cm) casters;

3. Combustible construction with a minimum clearance of 6-inches (15-cm) side and 6-inches (15-

cm) rear, and equipped with factory-supplied 6-inch (15-cm) adjustable legs or 5-inch (13-cm) casters.

CAUTION

Local building codes usually prohibit a fryer with its open tank of hot oil from being installed

beside an open flame of any type, whether a broiler or the open burner of a range.

C. Installation Standards:

1. U.S. installations must meet: 2. Canadian installations must meet:

American National Standard Institute CAN 1-B149 Installation Codes ANSI Z83.11 Canadian Gas Association American Gas Association 55 Scarsdale Road 8501 E. Pleasant Valley Road Don Mills, ONT, M3B 2R3 Cleveland, OH 44131

National Electrical Code Canadian Electric Code c22.1, part 1 ANSI/NFPA #70 Canadian Standards Association American National Standard Institute 178 Rexdale Blvd. 1430 Broadway Rexdale, ONT, M9W 1R3 New York, NY 10018

NFPA Standards #96 and #211 National Fire Protection Association 470 Atlantic Avenue Boston, MA 02110

3. CE/EXPORT STANDARDS: Fryer installation must conform with local codes, or in the absence of

local codes, to the appropriate national or European Community (CE) standards.

2-2

2.5 Air Supply and Ventilation

Keep the area around the fryer clear to prevent obstruction of combustion and ventilation airflow as well as for service and maintenance.

A. Do not connect this fryer to an exhaust duct. B. Correct installation and adjustment will ensure adequate airflow to the fryer system. C. A commercial, heavy-duty fryer must vent its combustion wastes to the outside of the building.

A deep-fat fryer must be installed under a powered exhaust hood, or an exhaust fan must be provided in the wall above the unit, as exhaust gas temperatures are approximately 800-1000°F (427-538°C). Check air movement during installation. Strong exhaust fans in the exhaust hood or in the overall air conditioning system can produce slight air drafts in the room.

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 fryer cabinet for storage or store items on shelving over or behind

the fryer. Exhaust temperatures can exceed 425ºC and may damage or melt items stored in or near the fryer.

F. Adequate 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 18-inches (45-cm) should be maintained between the flue(s) and the lower edge of the exhaust hood filter.

G. Filters and drip troughs should be part of any industrial hood, but consult local codes before

constructing and installing any hood. The duct system, the exhaust hood and the filter bank must be cleaned on a regular basis and kept free of grease.

2.6 Equipment Installed at High Altitudes:

A. The fryer input rating (BTU/hr) is for elevations up to 2,000 feet (610-m). For elevations above

2,000 feet (610-m), the rating should be reduced four percent (4) for each additional 1,000 feet (305-m) above sea level.

B. The correct orifices are installed at the factory if operating altitude is known at time of the

customer’s order.

2.7 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 they will be needed.

B. After unpacking, immediately check the equipment for visible signs of shipping damage. If

damage has occurred, contact the carrier and file the appropriate freight claims. Do not contact the factory. Shipping damage responsibility is between the carrier and the dealer.

2-3

If your equipment arrives damaged:

1. File claim for damages immediately, regardless of extent of damage.

2. Visible loss or damage: Be sure this is noted on the freight bill or express receipt and is

signed by the person making the delivery.

3. Concealed loss or damage: If damage is unnoticed until equipment is unpacked, notify freight

company or carrier immediately, and file a concealed damage claim. This should be done within fifteen (15) days of date of delivery. Be sure to retain container for inspection.

NOTE: Dean Does Not Assume Responsibility for Damage or Loss Incurred in Transit.

C. Take off the filter support brace and remove the filter pan from the cabinet of the two left fryers. D. Casters are pre-installed on the fryer unit and the carton is furnished with three unloading ramps.

Remove the braces from the front casters by taking out the securing bolts. Carefully roll the unit down the ramps from the front (cooking side).

E. Remove all plastic skin from sides, front, and doors of the unit. Failure to do this will melt the

plastic and make it very difficult to remove later.

2-4

DECATHLON SERIES GAS FRYERS

CHAPTER 3: INSTALLATION

3.1 Installing the Fryer

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: Remove all weight from each leg before moving a fryer with legs

installed. Do not slide the fryer on the legs.

C. If a leg becomes damaged, contact your service agent for immediate repair/replacement.

3.2 Leveling the Fryer (Fryers equipped with legs only)

A. All Installations: If the floor is uneven or has a definite slope, it is recommended to place

the fryer on an even platform.

B. Place a carpenter’s spirit level across the top of the fryer and level the unit both front-to-back

and side-to-side. If it is not level, the unit may not function efficiently, the oil may not drain properly for filtering and in a line-up it may not match adjacent units.

C. Adjust to the high corner and measure with the spirit level. If floor is uneven, level the unit

with the screw adjustments on each leg (ensure minimum clearances as discussed in Chapter 2 are maintained during the leveling procedure).

D. Re-leveling: If the fryer is moved, re-level the fryer following the above instructions. E. The install must be reviewed at the time of installation to ensure it meets the intent of these

instructions.

CAUTION

Fryers must be at room temperature, empty of oil, and if fitted with legs lifted during

movement to avoid damage and possible bodily injury.

WARNING

Hot shortening can cause severe burns. Avoid contact. Under all circumstances, oil

must be removed from the fryer before attempting to move it to avoid oil spills, and

the falls and severe burns that could occur. This fryer may tip and cause personal

injury if not secured in a stationary position. See instruction manual.

3-1

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. The fryer cannot be curb mounted and must be equipped with either legs or casters provided.

B. After unpacking, use a pallet or lift jack to raise the unit approximately 12 inches before

installing the casters.

C. Align the caster or leg base holes with the leg support assembly and insert bolt. Install the

washers and nut hand-tight, and repeat for all four holes in caster/leg base assembly.

D. Tighten the caster/leg against the leg support assembly by using appropriate tools. Ensure

that all four bolts are evenly tightened.

E. For fryers with casters, there are no built-in leveling devices. The floor where the fryers

are installed must be level.

Front Channel or Rear Channel

Front or Rear Leg with Mounting Plate

Front View

Adjust as needed

1/4-20 x 3/4 Hex Bolt

Front Channel or

Rear Channel

Leg Support Assembly

Washer

1/4-20 Hex Head Locknut

1/4-20 x 3/4 Hex Bolt

Rear Side View

Optional Caster-

Rear Only

Rear Caster—5" Rigid

Optional Caster-

Front Only

Front Caster—5" Swivel w/Brake

Caster/Leg Installation and Adjustment

WARNING

Dean fryers equipped with legs are for permanent installations. Fryers fitted with

legs must be lifted during movement to avoid damage and possible bodily injury. For

a moveable or portable installation, Dean optional equipment casters must be used.

Questions? Call 1-800-551-8633

3-2

3.4 Gas Categories

Dean Decathlon Series Gas Fryers have obtained CE markings for countries and gas categories listed in the table below:

Countries Supply Pressures and

Gas (mbar)

G20 20/25 I2E (R) B G20 20

BE Belgium

G31 37 I3P G20 20 I2E G20 20

DE Germany

G31 50 I3P

DK Denmark G20 20 I2H IT Italy G20 20 I2H

G20 20 G20/G25 20/25

ES Spain

G31 37 and 50 G20/G25 20/25 G25 25

FR France

G31 37 and 50 G20 20 G20 20

GB Great Britain

G31 37

Appliance Categories

II2H3P LU Luxembourg

II2ESI3P NL

II2H3P PT Portugal

Countries Supply Pressures and

GR Greece

IR Ireland

The Netherlands

Gas (mbar)

G31 37 and 50

G31 37

G31 50

G31 37

Appliance Categories

II2H3P

II2E3P

II2L3P

II2H3P

3.5 Gas Connections

A. The gas supply (service) line must be the same size or greater than the fryer inlet line. This

fryer is equipped with a 3/4" (19 mm) male inlet. The gas supply line must be sized to accommodate all the gas-fired equipment that may be connected to that gas supply. Consult your contractor, gas company, supplier, or other knowledgeable authorities.

Recommended Gas Supply Line Sizes

Gas Types Number of Fryers

1 2 to 3 4 or more (*)

Natural Gas 3/4" (19 mm) 1" (25 mm) 1 1/4" (33 mm) Propane Gas 1/2" (13 mm) 3/4" (19 mm) 1" (25 mm)

(*) When exceeding 18 feet (6 meters) for a configuration of more than four fryers, it is necessary

to provide a 1 1/4" (33 mm) rigid gas connection.

CAUTION

All connections must be sealed with a joint compound suitable for the gas being

used, and all connections must be tested with a soapy solution before lighting any

pilots.

3-3

3.5 Gas Connections (cont.)

B. Rigid Connections: Check any installer-supplied intake pipe(s) visually and clean threading

chips, or any other foreign matter before installing into a service line. If the intake pipes are not clear of all foreign matter, the orifices will clog when gas pressure is applied. Seal pipe joints with a sealant resistive to LP gas. When using thread compound on gas piping, use very small amounts and only on male threads. Use a pipe thread compound that is not affected by the chemical action of LP gases. DO NOT apply thread compound to the first two pipe threads--doing so will cause clogging of the burner orifices and control valve.

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 Pressure: The fryer and shut-off valve must be disconnected from the gas

supply during any pressure testing of the system.

1. External gas regulators are not normally required on this fryer. A safety control valve

protects the fryer against pressure fluctuations. If the incoming pressure is in excess of ½" PSI (3.45 kPa/35 mbar), a step-down regulator will be required.

CAUTION

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 ½ PSI (3.45 kPa/35 mbar).

The fryer and its individual shut-off valve must be disconnected from the gas supply

piping system during any pressure testing of the gas supply system at test

pressures in excess of ½ PSI (3.45 kPa/35 mbar).

E. Manifold Pressure: Your local service technician should check the manifold pressure with a

manometer.

1. Check the rating plate for manifold gas pressures. Natural gas units normally require 4"

W.C., and propane units normally require 11" W.C. gas pressure.

2. Double check the arrow forged into the bottom of the regulator body, which shows gas

flow direction. It should point downstream towards the fryers. The air vent cap is also part of the regulator and should not be removed.

3. If a vent line from the gas pressure regulator is used, it should be installed in

accordance with local codes or in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1-(latest edition).

3-4

3.5 Gas Connections (cont.)

WARNING

Use a diluted soap solution to find potentially dangerous gas leaks when making

new connections.

F. Regulators can be adjusted in the field, but it is recommended that they not be tampered with

unless the part is known to be out of adjustment or serious pressure fluctuations are found to exist and can be solved no other way.

G. Only qualified service personnel should make adjustments to the regulators. 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. While the valve can be adjusted in the field, only qualified service personnel should make any adjustments with the proper test equipment.

WARNING

If gas odors are detected, the gas supply must be shut off at the main shut-off valve.

The local gas company or FASC should be contacted immediately to rectify the

problem.

I. Flexible Couplings, Connectors and Casters:

1. If the fryer is to be installed with flexible couplings and/or quick-disconnect fittings, the

installer must use a heavy-duty AGA design-certified commercial flexible connector of at least 3/4" NPT (with suitable strain reliefs), in compliance with the Standard for Connectors for Movable Gas Appliances, ANSI Z21.69-(latest edition) and Addenda Z21.69a-(latest edition). Quick disconnect devices must comply with the Standard for Quick-Disconnect Devices for Use with Gas Fuel, ANSI Z21.41-(latest edition).

WARNING

Do not attach accessories to this fryer unless fryer 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 movement of the fryer. Clips are located on the back panel of the fryer for the attachment of restraints.

3. If disconnection of the restraint is necessary, this restraint must be reconnected after the

fryer has been returned to its originally installed position.

3-5

3.5 Gas Connections (cont.)

J. After hook-up, bleed the gas line of air to ensure that the pilot light will ignite quickly. K. CE Standards: If the unit is to be installed with flexible coupling, use a commercial flexible

coupling certified as NF D 36123 (or other national standard) or a quick disconnect device certified NF D 36124 (or other national standard).

3.6 Adjustments/Adaptation To Different Gases

A. Proper operation of appliances requires operator to scrupulously inspect the following

adjustments in terms of:

1. Gas inputs and pressures.

2. Voltage and polarities of electrical power supplies.

B. Dean gas fryers are manufactured to use the type of gas and pressure specified on the rating

plate. When changing to a different gas, adaptation must be performed by qualified personnel. Failure to use qualified personnel will void the Frymaster warranty.

3.6.1 CE Specifications

3.6.1.1 Gas Types and Specifications

MODEL

D20G 15

D50G 30

D60G 37.5

D80G 37.5

INPUT

(kW)

GAS

TYPE

G20 G25 G31

ORIFICE

MM (INCH)

2.40(#42)

1.51(#53)

2.40(#42)

1.51(#53)

2.40(#42)

1.51(#53)

2.40(#42)

1.51(#53)

ORIFICE

PART NO.

14-0067-10Blu 14-0067-10Blu

14-0067-2Red

14-0067-10Blu 14-0067-10Blu

14-0067-2Red

14-0067-10Blu 14-0067-10Blu

14-0067-2Red

14-0067-10Blu 14-0067-10Blu

14-0067-2Red

QTY/

COLOR

2/BLUE 2/BLUE

2/RED

4/BLUE 4/BLUE

4/RED

5/BLUE 5/BLUE

5/RED

5/BLUE 5/BLUE

5/RED

EQUIPMENT

PRESSURE

MBAR INCH WC

10 15 27

4.0

6.0

10.8

4.0

6.0

10.8

4.0

6.0

10.8

4.0

6.0

10.8

PRESSURE

MBAR

20MBAR 25MBAR 37MBAR

PILOT

ASSEMBLY

14199-1CE 14199-1CE 14199-2CE

3-6

3.6.1.2 Adjustments to Different Gas Types

Gases and Gas Supply Pressure*

Orifice Diameter Burner Marking

G20

20 mbar

G25

25 mbar

G31

37/50 mbar

2.40 mm 2.40 mm 1.51 mm

"blue" marking "blue" marking "red" marking

TJ013

Pilot Marking

Gas pressure at the

TJ024 TJ024

"red"

10 15 27

regulator (mbar)*

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" illustrations on page 3-8. (Pilot Flame

Adjustment: Turn the pilot adjustment screw clockwise/counter-clockwise until the desired flamevolume is achieved).

3.6.2 Gas Conversion Procedures

See page 3-8 for gas valve illustrations when performing the following conversions.

When converting from G20 to G25 gas, the following procedures apply:

♦ Equipment replacement is not required. ♦ Adjust orifice gas pressure by turning the gas valve adjustment screw (See Section 3.6.1.1

for various gas types and pressures).

♦ After adjustment, seal the screw.

When converting from G20 (or G25) gas to G31 propane (or vice-versa), the following procedures apply:

♦ Burner orifices and pilot MUST be replaced (See page 3-9 for required components). ♦ Adjust orifice gas pressure by turning the gas-valve adjustment screw (See Section 3.6.1.1

for various gas types and pressures).

♦ After adjustment, seal the screw. ♦ Affix new label "fryer equipped for: <gas family/# mbar>" to the rating plate. Remove any

reference to the previously used gas from the rating plate.

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:

♦ Check pilot-adjustment and adjust as necessary. ♦ Other adjustments are not necessary.

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