Frymaster D60, D20, D80, D50 User Manual

Decathlon Series Gas Fryers (CE)

Installation & Operation Manual

D20, D50, D60 & D80 Series

*8195706*

CE ONLY

Price: $10.00

Service Hotline [phone]

819-5706

JUNE 2002

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 detects a gas leak

must be posted in a prominent location. This information can be obtained from the local gas

company or gas supplier.

DANGER

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

No structural material on the fryer should be altered or removed to accommodate placement of

the fryer under a hood. Questions? Call the Dean Service Hotline at 1-800-551-8633.

WARNING

Do not bang fry baskets or other utensils on the fryer’s joiner strip. The strip is present to seal

the joint between the frypot. Banging fry baskets on the strip to dislodge shortening will distort

the strip, adversely affecting its fit. It is designed for a tight fit and should only be removed for

cleaning.

IMPORTANT

Safe and satisfactory operation of Dean equipment depends upon its proper installation.

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

Community (CE) Standards.

NOTICE

IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART F OR THIS ENODIS

EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART PURCHAS ED

DIRECTLY FROM FRYMASTER/DEAN, OR ANY OF ITS AUTHORIZED SERVICE CENTE RS,

AND/OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL CONFIGURAT ION, THIS

WARRANTY WILL BE VOID. FURTHER, FRYMASTER/DEAN AND ITS AFFILIATES WILL NOT BE

LIABLE FOR ANY CLAIMS, DAMAGES OR EXPENSES INCURRED BY THE CUSTOMER WHICH

ARISE DIRECTLY OR INDIRECTLY, IN WHOLE OR IN PART, DUE TO THE INSTALLATION OF

ANY MODIFIED PART AND/OR PART RECEIVED FROM AN UNAUT HORIZED SERVICE CENTER.

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 and Unpacking Equipment 2-1

2.2 General 2-1

2.3 Principles of Operation 2-2

2.4 Rating Plate 2-3

2.5 Pre-Installation 2-3

2.6 Air Supply and Ventilation 2-4

2.7 Equipment Installed at High Altitudes 2-5

2.8 Conversion of Units 2-5

3. INSTALLATION 3-1

3.1 Installing the Fryer 3-1

3.2 Leveling the Fryer (Fryers equipped with legs only) 3-1

3.3 Installing Casters and Legs 3-2

3.4 Gas Categories 3-3

3.5 Gas Connections 3-4

3.6 Adjustments/Adaptation to Different Gases 3-7

3.7 Electrical Connections 3-11

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. TROUBLESHOOTING 7-1

7.1 General 7-1

7.2 Pilot Burner Malfunction 7-1

7.3 Main Burner Malfunctions 7-2

7.4 Thermatron Calibration 7-3

7.5 Wiring Diagrams 7-4

7.6 Recommended Spare Parts 7-7

FINDING YOUR WAY AROUND THE DEAN DECATHLON

Top Cap

Electronic Operating

Thermostat

Burners

Basket Hanger

Flue Cap

Frypot

1.5” Round Drains

Drain Valve Handle (Red)
Oil Return Handle (Yellow)
Drain Flush Handle (Blue)

Filter Unit

Drain Tubes

Drain Tubes

3” Round Drains (SCFD models)

A

DECATHLON SERIES GAS FRYERS (CE)

CHAPTER 1: INTRODUCTION

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 Dean Decathlon gas units sold in English­speaking countries, including those in the European Union. Where conflicts exist between
instructions and information in this manual and local or national codes of the country in which
the equipment is installed, installation and operation shall comply with those codes.

This appliance is only for professional use and shall be used by qualified personnel as defined
in Section 1.7.

1.2 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

1.3 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 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.

1-1

DECATHLON SERIES GAS FRYERS (CE)

CHAPTER 1: INTRODUCTION

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 you more efficiently, always provide the service technician with the model
number, gas type, serial number, and the nature of the problem.

1.5 Computer Information

This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to Part 15 of the FCC rules. While this device is a verified Class A device, it has been
shown to meet the Class B limits. These limits are designed to provide reasonable protection against
harmful interference when the equipment is operated in a commercial environment. This equipment
generates, uses and can radiate radio frequency energy and, if not installed and used in accordance
with the instruction manual, may cause harmful interference to radio communications. Operation of
the equipment in a residential area is likely to cause harmful interference in which case the user will
be required to correct the interference at his own expense.

The user is cautioned that any changes or modifications not expressly approved by the party
responsible for compliance could void the user's authority to operate the equipment.

If necessary, the user should consult the dealer or an experienced radio and television technician for
additional suggestions.

The user may find the following booklet prepared by the Federal Communications Commission
helpful: "How to Identify and Resolve Radio-TV Interference Problems". This booklet is available
from the U.S. Government Printing Office, Washington, DC 20402, Stock No. 004-000-00345-4.

1.6 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.

CAUTION

Example of a CAUTION box.

1-2

DECATHLON SERIES GAS FRYERS (CE)

CHAPTER 1: INTRODUCTION

1.6 Safety Information (cont.)

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.

1.7 Service Personnel

1.7.1 Definitions

A. Qualified and/or Authorized Operating Personnel

1. Qualified/authorized operating personnel are those who have carefully read the information
in this manual and have familiarized themselves with the equipment functions, or have had
previous experience with the operation of equipment covered in this manual.

B. Qualified Installation Personnel

1. Qualified/authorized personnel are those who have carefully read the information in this
manual and have familiarized themselves with the equipment functions, or who have had
previous experience with the operation of the equipment covered in this manual.

C. Qualified Service Personnel

1. Qualified service personnel are those who are familiar with Dean equipment and have been
authorized by Dean to perform service on Dean equipment. All authorized service
personnel are required to be equipped with a complete set of service parts manuals and stock
a minimum amount of parts for Dean equipment. A list of Dean Factory Authorized Service
Centers (FASCs) was included with the fryer when shipped from the factory. Failure to use
qualified service personnel will void the Dean warranty on your equipment.

1-3

DECATHLON SERIES GAS FRYERS (CE)

CHAPTER 2: IMPORTANT INFORMATION

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 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.

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 15 days of date of delivery. Be sure to retain container and all packing
materials for inspection.

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

C. Frying systems with built-in filtration: Take off the filter support brace and remove the

filter pan from the cabinet.

D. Remove all plastic skin from sides, front, and doors of the fryer(s). Failure to do this prior to

initial fryer operation will make it very difficult to remove later.

2.2 General

Qualified, licensed, and/or authorized installation or service personnel only (as defined in
Section 1.7) should perform the following:

?? Installation and service on Dean equipment.
?? Conversion of this appliance from one gas type to another.

Failure to use qualified, licensed, and/or authorized installation or service personnel to install,
convert to another gas type or otherwise service this equipment will void the Dean warranty
and may result in damage to the equipment or injury to personnel.

2-1

DECATHLON SERIES GAS FRYERS (CE)

CHAPTER 2: IMPORTANT INFORMATION

2.2 General (cont.)

Where conflicts exist between instructions and information 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.

CAUTION

Building codes prohibit a fryer with its open tank of hot oil/shortening from being

installed beside an open flame of any type, including those of broilers and ranges.

Upon arrival, inspect the fryer carefully for visible or concealed damage. (See Receiving and
Unpacking Equipment in Section 2.1.)

CAUTION

Dean appliances equipped with legs are for stationary installations. Appliances

fitted with legs must be lifted during movement to avoid damage to the appliance

and bodily injury. For moveable installations, optional equipment casters must be

used. Questions? Call 1-800-551-8633.

2.2.1 Product Description

Dean Decathlon Series gas fryers are energy efficient, tube-style, gas-fired units. All units are
shipped completely assembled with accessories packed inside the frypot. 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.

2.3 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.

2-2

DECATHLON SERIES GAS FRYERS (CE)

CHAPTER 2: IMPORTANT INFORMATION

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 (inches W.C.) 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.

2.5 Pre-Installation

DANGER

No structural material on the fryer should be altered or removed to accommodate

placement of the fryer under a hood. Questions? Call the Frymaster/Dean Service

Hotline at 1-800-551-8633.

DANGER

Do not connect this appliance to the gas supply before reviewing all information in

this chapter.

A. General: Only licensed personnel (as defined in Section 1.7) 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. Dean Decathlon Series (CE) gas fryers require 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/system.

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 15-cm (6-inch) adjustable
legs or 13-cm (5-inch) casters;

2-3

DECATHLON SERIES GAS FRYERS (CE)

CHAPTER 2: IMPORTANT INFORMATION

2.5 Pre-Installation (cont.)

3. Combustible construction with a minimum clearance of 15-cm (6-inch) side and 15-cm (6­inch) rear, and equipped with factory-supplied 15-cm (6-inch) adjustable legs or 13-cm (5­inch) casters.

DANGER

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

beside an open flame of any type, including those of broilers and ranges.

2-4

DECATHLON SERIES GAS FRYERS (CE)

CHAPTER 2: IMPORTANT INFORMATION

2.6 Air Supply and Ventilation (cont.)

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 45-cm (18-inches) 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.

2.7 Equipment Installed at High Altitudes

A. The fryer input rating [kW/hr (BTU/hr)] is for elevations up to 610-m (2000 feet). For

elevations above 610-m (2000 feet), the rating should be reduced 4 percent for each
additional 305-m (1000 feet) above sea level.

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

customer’s order.

2.8 Conversion of Units

Pressure:

1 mbar = 10,2 mm W.C. = 0,4-inch W.C.
20 mbar = 204 mm W.C. = 8-inch W.C.
1-inch W.C. = 25,4 mm W.C. = 2,5 mbar

Heat Input:

1 kW = 3410 BTU/hr
100 BTU/hr = 0,0293 kW

Temperature:

0° Celsius = 32° Fahrenheit
Temperature in degrees Celsius = (Temperature in degrees Fahrenheit (F) – 32) x 0,555
100° Celsius = (212° Fahrenheit – 32) x 0,555

2-5