Frymaster FPD, SCFD, CFD User Manual

Decathlon Series Gas Fryers

Service & Parts Manual

D, CFD, SCFD, FPD,

and Common Cabinet Models

NON-CE &

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

24-Hour Service Hotline

1-800-551-8633

FEBRUARY 2007

*8195922*

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 FRYMASTER FACTORY AUTHORIZED SERVICE CENTER.

DANGER

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

other cooking appliance.

DANGER

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.

DANGER

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; The Propane Installation

Code, CAN/CGA-B149.2; or The latest edition of the National Electric Code, N.F.P.A. 70.

NOTICE

If, during the warranty period, the customer uses a part for this Enodis equipment other than an

unmodified new or recycled part purchased directly from Frymaster and Dean, or any of its

authorized service centers, and/or the part being used is modified from its original

configuration, this warranty will be void. Further, Frymaster and 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 unauthorized service center.

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.

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.

WARNING

Drawings and photos used in this manual are intended to illustrate operational, cleaning and

technical procedures and may not conform to on-site management operational procedures.

WARNING

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

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

8633.

This equipment is to be installed in compliance with the basic plumbing code of The Building

Officials and Code Administrators International, Inc. (BOCA) and the Food Service Sanitation

Manual of the Food and Drug Administration.

COMPUTERS

FCC

This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions:

1) This device may not cause harmful interference, and 2) This device must accept any interference

received, including interference that may cause undesired operation. While this device is a verified Class

A device, it has been shown to meet the Class B limits.

CANADA

This digital apparatus does not exceed the Class A or B limits for radio noise emissions as set out by the

ICES-003 standard of the Canadian Department of Communications.

Cet appareil numerique n’emet pas de bruits radioelectriques depassany les limites de classe A et B

prescrites dans la norme NMB-003 edictee par le Ministre des Communcations du Canada.

DANGER

THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE

CANCER AND/OR BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM. Operation, installation, and servicing of this product could expose you to airborne particles of glasswool or ceramic fibers, crystalline silica, and/or carbon monoxide. Inhalation of airborne

particles of glasswool or ceramic fibers is known to the State of California to cause cancer.

Inhalation of carbon monoxide is known to the State of California to cause birth defects or other

reproductive harm.

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 fry vessels. 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.

Decathlon Series Gas Fryers

Service and Parts Manual

TABLE OF CONTENTS

1. SERVICE PROCEDURES……..……..……………………………………………...

1.1 Functional Description............................................................................................1-1

1.2 Accessing Fryers for Service...................................................................................1-8

1.3 Cleaning the Gas Valve Vent Tube (if applicable)..............................................1-10

1.4 Adjusting Burner Manifold Gas Pressure..........................................................1-10

1.5 Adjusting the Pilot Flame......................................................................................1-11

1.6 Calibrating the Thermatron Controller and Backup Thermosta t....................1-11

1.7 Replacing Fryer Components...............................................................................1-13

1.8 Troubleshooting and Problem Isolation..............................................................1-32

1.9 Troubleshooting Guides........................................................................................1-41

1.10 Wiring Diagrams....................................................................................................1-43

2. PARTS LIST…….…………………………………..……………………………….

2.1 Decathlon Primary Components............................................................................2-1

2.2 Control Panel Options; D60 Series.......................................................................2-14

2.3 Optional Components and Controllers................................................................2-15

2.4 Transformers and Component Boxes; Multi-batteried Decathlon...................2-18

2.5 Oil Drain Manifold Components..........................................................................2-20

2.6 Oil Return Manifold Components........................................................................2-24

2.7 Oil Return and Oil Flush Components................................................................2-28

2.8 Under Fryer Filter (UFF) Components; D50 and D60 Series............................2-32

2.9 Single Under Fryer Filter (SUFF) Components..................................................2-37

2.10 Basket Lift Components; D50, D60, and D80......................................................2-41

2.11 Trough, Holster, and Cover Components; D60 and D80 Series........................2-43

FINDING YOUR WAY AROUND THE DEAN DECATHLON

Top Cap

Electronic Operating

Thermostat

Burners

Basket Hanger

Flue Cap

Frypot

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

Filter Unit

Drain Tubes

)

DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.1 Functional Description

Decathlon Series gas fryers contain a welded steel frypot (stainless or cold-rolled) heated by gas flames diffused evenly through tubes built into the frypot.

Flames originate from orifices in a burner manifold positioned beneath cast-iron burners. The burners are positioned in the tube openings, at the front of the frypot. The diameter of the orifices differs for natural (CE:G20/G25) and LP (CE:G31) gas as indicated in the accompanying table.

NON-CE (Altitudes of 2000 feet or less

MODEL

D20G 50

INPUT

(BTU)

GAS

TYPE

NAT

ORIFICE

(INCH)

2.18(#44)

1.40(#54)

ORIFICE

PART NO.

810-2050 810-2324

QTY

2 2

EQUIPMENT

PRESSURE

MBAR INCH W.C.

27.5

D50G 85

D50G(HP) 120

D50GDDHP 115

D60G 112

D60G(HP) 150

D80G 122

D80G(HP) 165

CE ONLY (Altitudes of 2000 feet or less

MODEL

D20G 15,0

INPUT

(kW)

NAT

GAS

TYPE

G20 G25 G31

2.08(#45)

1.32(#55)

2.53(#39)

1.51(#53)

2.44(#41)

1.51(#53)

2.08(#45)

1.32(#55)

2.53(#39)

1.51(#53)

2.26(#43)

1.40(#54)

2.58(#38)

1.61(#52)

ORIFICE

(INCH)

2,40 2,40 1,51

14-0067-45

810-2441

810-2048 810-2059

14-0067-41

810-2059

14-0067-45

810-2441

810-2048 810-2059

810-2049 810-2324

810-2062 810-2063

ORIFICE

PART NO.

810-2060 810-2060 810-2059

4 4

5 5

QTY/

COLOR

2/BLUE 2/BLUE

2/RED

27.5

EQUIPMENT

PRESSURE

MBAR INCH W.C.

10,0 15,0 27,0

4,0 6,0

10,8

G20

D50G 30,0

D60G 37,5

D80G 37,5

G25 G31

G20 G25 G31

2,40 2,40 1,51

810-2060 810-2060 810-2059

4/BLUE 4/BLUE

4/RED

5/BLUE 5/BLUE

5/RED

5/BLUE 5/BLUE

5/RED

10,0 15,0 27,0

4,0 6,0

10,8

4,0 6,0

10,8

4,0 6,0

10,8

1-1

DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.1 Functional Description (cont.)

An electromechanical gas valve regulates gas flow to the manifold. Decathlon Series gas fryers are equipped with either a 120V valve system or a 24V valve system. Unit configurations include either a pilot ignition system (standing pilot) or an electronic ignition system.

Pilot System Configuration

The pilot system is comprised of the pilot orifice, pilot hood, and a thermopile. The pilot serves two purposes: light the burner and heat the thermocouple (some systems incorporate a thermopile). In operation, the thermocouple is in contact with the pilot flame and generates millivolts. The millivolt output energizes the gas valve pilot coil, which in turn opens the pilot valve. If the pilot flame is extinguished, the gas valve pilot coil loses voltage and the pilot valve closes. The main valve of the gas valve will not open if the pilot valve is not open. The pilot flame must be manually lit when the fryer is first placed into operation. A separate 120V circuit, activated by the fryer ON/OFF switch, provides voltage through the Thermatron to the gas valve main coil, which opens the main valve.

Electronic Ignition Configuration

In units configured for electronic ignition, an ignition module connected to an ignitor assembly replaces the pilot system. The ignition module performs three important functions: provide an ignition spark, supply voltage to the gas valve, and proof the pilot flame.

1-2

DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

Electronic Ignition Configuration (cont.)

The module contains a 60-second time delay circuit and a coil that activates the gas valve. The ignitor assembly consists of a spark plug, a pilot, and a flame sensor element.

At start-up the ON/OFF switch is placed in the ON position, supplying 12 VDC to the heat control circuitry in the controller or computer and to one side of the heat relay coil on the interface board. If resistance in the temperature probe indicates the temperature in the frypot is below 180°F (82°C), the current flows through a melt cycle circuit where a timer switch alternately closes for 3 seconds and opens for 24 seconds. If the temperature is 180°F (82°C) or above, the current flows through a heat circuit, bypassing the timer switch. In either case, current is supplied to the other leg of the heat relay coil which then closes an electronic switch in the 24 VAC circuit to provide current to the ignition module. NOTE: The listed melt cycle times and exit temperature pertain to the Compu-Fry computer only.

Circuitry in the ignition module sends 24 VAC current to the gas valve via a normally closed highlimit switch and a drain safety switch. Simultaneously, the module causes the ignitor to spark for up to 60 seconds to light the pilot flame. A flame sensor verifies that the pilot is lit by measuring the flow of microamps through the flame. If the pilot does not light (or is extinguished), current to the ignition module is interrupted, preventing the main valve from opening, and the ignition module "locks out" until the power switch is turned OFF, then back ON.

A temperature probe monitors the temperature in the frypot. When the programmed setpoint temperature is reached, resistance in the probe causes the heat cycle circuitry in the controller to interrupt current flow through the heat relay. This in turn interrupts the 24 VAC current to the ignition module, resulting in closure of the gas valve.

NOTE: In September 2006, these modules were replaced with black Honeywell modules (Kit, 826-

2117). Operationally they are similar. The new modules have a 4.5 second delay before sparking and lockout at 90 seconds. Unlike previous modules, microamp readings on the new black modules will move up and down as the module pulses on and off and this is an indication that the module is functioning.

When installing the new modules into an older unit with a Fast GO board, a resistor (provided in module kit) is needed to adjust melt cycle to accommodate the 4.5 second delay.

Control Options

Decathlon Series gas fryers may be equipped with operating thermostat controls (optional backuponly; available with electronic thermostat or computer), Thermatron, or Compu-Fry computers.

In fryers equipped with Thermatron, the fryer is turned on and off by means of a rocker switch and the temperature is set by adjusting a potentiometer. An interface board is located in the component box (shield) behind the control panel (computer-equipped) or in a component box inside the cabinet (Thermatron-equipped).

1-3

DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

Interface Boards

The interface board provides a link between the controller/computer and the fryer’s individual components without requiring excessive wiring, and allows the controller to execute commands from one central point. Two types of interface boards may be used in Decathlon Series gas fryers; the type used depends on the fryer configuration.

In units configured for Thermatron, P/N 826-2086 (115/230V) is used; in units configured for Compu-Fry computers, P/N 106-6710 is used.

IFB 826-2086 (115/230V): These boards are used in Decathlon fryers equipped with Thermatron control systems.

THERMATRON P/N 826-2086

Thermatron systems incorporate a temperature probe, a potentiometer, and a temperature control circuit board. This system is more accurate and reliable than a standard thermostat. The temp erature probe measures oil temperature via resistance (ohms); as oil temperature rises, resistance decreases. The potentiometer sets the oil temperature via resistance (ohms). The temperature control circuit board compares the resistance from the probe and potentiometer and cycles the burner on and off as necessary.

1-4

DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

Interface Boards (cont.)

IFB 106-6669 & 106-6710: These interface boards are used in Decathlon fryers with Frymaster computer control systems.

INTERFACE BOARD P/N 106-6669 INTERFACE BOARD P/N 106-6710

FREQUENTLY USED TEST POINTS FOR INTERFACE BOARD P/N 806-4549 (previous style)

Test Meter Setting Pins Test Results

12VAC Power to Controller 50VAC Scale 1 and 3 on J3 12-18 24VAC Power to Right Module 50VAC Scale 8 on J3 and GROUND 22-28 24VAC Power to Left Module 50VAC Scale 8 on J1 and GROUND 22-28 12VDC Power to Right BL Relay 50VDC Scale 7 on J2 and 9 or 12 on J3 12-18 12VDC Power to Left BL Relay 50VDC Scale 9 on J2 and 9 or 12 on J1 12-18 24VAC Power to Right High-Limit 50VAC Scale 7 on J3 and GROUND 22-28 24VAC Power to Left High-Limit 50VAC Scale 7 on J1 and GROUND 22-28 120VAC Power* 250VAC Scale 11 on J3 and GROUND 110-125 120VAC Power To 120VAC Gas Valve* 250VAC Scale 10 on J3 and GROUND 110-125 Probe Resistance (Right)** R x 1000 Ohms 2 on J3 and 4 on J3 *** Probe Resistance (Left)** R x 1000 Ohms 2 on J1 and 4 on J1 ***

* Where Applicable

** Disconnect 15-pin harness from controller before testing probe circuit.

*** See Probe Resistance Charts in this chapter.

1-5

DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

Interface Boards (cont.)

P/N 806-4549 INTERFACE BOARD (previous style)

LED DIAGNOSTIC LIGHTS

12V

Indicates 12 VAC from transformer

24V

Indicates 24 VAC from transformer

Indicates 24 VAC to gas valve

PWR

Indicates 24 VAC to PWR via K1 (L) or K2 (R or F)

AIR

Not Applicable to Decathlon Series Gas Fryers

The board contains two heat relays (K2 and K3), and two basket lift relays (K1 and K4). NOTE: On factory-original units not equipped with basket lifts and on service interface boards, the board will have no basket lift relays installed.

INTERFACE BOARD

12 VAC TO CPTR

GROUND

12 VAC RETURN

COMPUTER

COMPUTER K4

NOT USED NOT USED

COMPUTER K1

RT ALARM OUT**

COMPUTER SOUND DEVICE

LT ALARM OUT*

COMPUTER

NOT USED NOT USED

TEMP PROBE

NOT USED

MAIN GAS VALVE

via HLS

24 VAC IN

BASKET LIFT (DN) K1

NOT USED NOT USED

AC COMMON AC CO MMON AC COMMON

BASKET LIFT (UP)

GROUND

RT HT RELAY (K3)

12 VDC TO RELAYS

LT HT RELAY (K2)

J1 PIN 2 & J3 PIN 2

J3 PIN 3

J3 PIN 1

ALR (RIGHT)

AD (LEFT)

J3 PIN 4

J1 PIN 4

NOT USEDNOT USED

J2 PIN 14TEMP PROBE

J2 PIN 15

NOT USEDNOT USED

NOT USED

V2D

PWR via K1

* Twin Vat configurations

** Single Vat configurations

J2 PIN 3

J2 PIN 14 TEMP PROBE

J2 PIN 1 12 VAC XFMR PIN 11

J2 PIN 13

NOT USED NOT USED

NOT USED

PWR via K2

AC Hot to 120VAC GV

12 VAC XFMR PIN 12

TEMP PROBE

NOT USED

MAIN GAS VALVE 24VACV1S OR V1D

K4 BASKET LIFT (DN)

via HLS

24 VAC IN

MAIN GAS VALVE 120VAC

via HLS

AC COMMON

BASKET LIFT (UP)

MOD 25V GROUND GROUND

MOD V2D

MOD 25V TERM

DRAIN SWITCH (OPT)

NOT USED NOT USED

GND

V2D

PWR

V2S

J1 PIN 8 via K1

LEFT TWIN VAT SINGLE OR RIGHT TWIN-VAT

CURRENT FLOW THROUGH INTERFACE

BOARD 806-4549 (previous style)

J1 PIN 7

J2 PIN 12

1-6

GROUND MO D 25V GROUND

J3 PIN 7

J3 PIN 8 via K2

J3 PIN 7

GND

V1D

PWR

ALR

V1S

MOD V1D*

MOD 25V TERM

DRAIN SWITCH (OPT)J2 PIN 10

MOD V1S**

DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

Thermostats

Different types of thermostats are used in Decathlon Series gas fryers, depending on fryer configuration.

Fryers equipped with an optional backup operating-thermostat and/or Thermatron use a dial to adjust temperature. In this configuration, the probe resistance varies directly with the temperature.

As the temperature rises, resistance decreases at a rate of approximately 2 ohms for every 1°F (approximately 3.7 ohms for every 1°C).

Fryers equipped with computer controls have a temperature probe. In this configuration, the probe resistance varies directly with the temperature. As the temperature rises, resistance increases at a rate of approximately 2 ohms for every 1°F (approximately 3.7 ohms for every 1°C). Circuitry in the computer monitors the probe resistance and controls burner firing when the resistance exceeds or falls below programmed temperatures (setpoints). The temperatures are programmed by means of a keypad on the face of the computer.

All Decathlon Series gas fryers are equipped with a high-limit thermostat. In the event that the fryer fails to control the oil temperature, the high-limit thermostat prevents the fryer from overheating to flash point. The high-limit thermostat acts as a normally closed power switch that opens when exposed to temperatures above 410°F/210°C (CE) to 450°F/232°C (non-CE). CE and non-CE highlimits are not interchangeable.

1.2 Accessing Fryers for Servicing

DANGER

Moving a fryer filled with cooking oil may cause spilling or splattering of the hot

liquid. Follow the draining instructions included with the fryer before attempting to

relocate a fryer for servicing.

1. Shut off the gas supply to the unit. Unplug the power cords. Remove any attached restraining

devices.

2. Disconnect the unit from the gas supply.

3. Relocate the fryer for service accessibility.

4. After servicing is complete, reconnect the unit to the gas supply, reattach restraining devices, and

plug in the electrical cords.

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.

1-7

DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

Restraints

Once the fryer has been positioned at the frying station, use a carpenter’s level placed across the top of the frypot to verify that the unit is level, both side-to-side and front-to-back.

To level fryers equipped with legs, the bottom of the legs can be screwed out up to one inch for leveling. Legs should also be adjusted so that the fryer(s) are at the proper height in the frying station.

For fryers equipped with casters, there are no built-in leveling devices. The floor where the fryers are installed must be level.

When the fryer is leveled in its final position, install the restraints provided with the unit to limit its movement so that it does not depend on or transmit stress to the electrical conduit or connection. Install the restraints in accordance with the provided instructions (see illustration below). If the restraints are disconnected for service or other reasons, they must be reconnected before the fryer is used.

DANGER Adequate means must be provided to limit the movement of this appliance without depending on or transmitting stress to electrical conduits or gas supply line. A restraint kit is provided with the fryer. If the restraint kit is missing contact your local Frymaster Factory Authorized Service Center (FASC) for part number 826-0900.

NOTE: If you need to relocate a fryer installed with legs, remove all weight from each leg

before moving. If a leg becomes damaged, contact your service agent for immediate repair or replacement.

DANGER Hot oil 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, falls, and severe burns. This fryer may tip and cause personal injury if not secured in a stationary position.

1-8

DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.3 Cleaning the Gas Valve Vent Tube (if applicable)

1. Set the fryer power switch and the gas valve to the OFF position.

2. Carefully unscrew the vent tube from the gas valve. NOTE: The vent tube may be straightened

for ease in removal.

3. Pass a piece of ordinary binding wire (.052 inch diameter) through the tube to remove any

obstruction. Remove the wire and blow through the tube to ensure it is clear.

4. Reinstall tube and bend so that the opening is pointing downward.

1.4 Adjusting Burner Manifold Gas Pressure

WARNING

This task should be performed by qualified service personnel only.

1. Ensure that the gas valve knob is in the OFF position.

2. Remove the pressure tap plug from the gas valve (see arrows in photos below for location).

Pilot Ignition Valve

(Line Voltage)

Non-CE Electronic

Ignition Valve

CE Pilot Ignition Valve

3. Insert the manometer fitting into the pressure tap hole.

4. Place the gas valve in the ON position then place the fryer power switch in the ON position.

When the burner lights and continues to burn, check the gas pressure reading against the table on page 1-1.

5. To adjust burner gas pressure, remove the cap from the gas valve regulator and adjust to correct

pressure.

6. Place the fryer power switch and the gas valve in the OFF position. Remove the manometer

fitting from the pressure tap hole and reinstall the pressure tap plug.

1-9

DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.5 Adjusting the Pilot Flame

1.5.1 Main Pilot

1. Remove the cap from the pilot adjustment screw hole on the gas valve.

2. Using a small, flat-tipped screwdriver, turn the pilot adjusting screw counterclockwise to

increase length of flame or clockwise to decrease length of flame. Adjust to obtain a flame from 1 inch to 1½ inches long.

3. Reinstall the pilot adjustment screw cap.

1.5.2 Trailing Pilot

In older Decathlon units, the trailing pilot may need adjusting. Adjust the trailing pilot valve located on the burner manifold until a flame from 1 inch to 1½ inches long is obtained. Current production units do not have an adjustment.

1.6 Calibrating the Thermatron

(and Optional Backup Operating Thermostat)

1.6.1 Thermatron

1. Fill the frypot to the lower OIL-LEVEL line with cooking oil. If solid shortening is used, it must

be melted before starting the calibration procedure.

2. Ensure the fryer ON/OFF switch is in the OFF position and light the pilot.

3. Place the fryer ON/OFF switch in the ON position. Set the electronic thermostat dial to 325°F

(162°C).

4. Allow the oil to equalize at setpoint temperature. This is evident when the burners have cycled

on and off several times.

5. Insert a thermometer or pyrometer into the frypot within 3 inches of the probe bulb. Ensure the

tip of the thermometer/pyrometer does not touch the frypot burner-tube.

6. If the temperature on the thermometer is higher or lower than 325°F (162°C), the knob is out of

calibration.

7. Calibrate the knob by first loosening the setscrew and slowly turn the knob to match the

temperature reading of the thermometer. Tighten the setscrew, ensuring the knob does not move on the shaft during tightening.

8. Allow burners to cycle on and off several times, then recheck oil temperature as described in

Step 5. If the thermostat dial temperature matches the thermometer temperature, the thermostat is calibrated. If not, repeat Step 7.

1-10

DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.6.2 Backup Operating Thermostat (Optional)

1. Fill the frypot to the lower OIL-LEVEL line with oil. If solid shortening is used, it must be

melted before starting the calibration procedure.

2. Light the pilot.

3. Set the temperature control knob to 350°F/177°C.

4. Let the burners cycle on and off automatically three times in order for the cooking oil

temperature to become uniform. If necessary, stir to get all shortening in the bottom of the frypot melted.

5. Insert a thermometer or pyrometer probe into the oil, with the end near the fryer temperature-

sensing probe.

NOTE: The temperature-sensing probe is mounted on the frypot tube.

6. When the burner starts for the fourth time, the thermometer/pyrometer reading should be within

the range 335-360°F (168-182°C). If it is not, calibrate as follows: a. Remove the thermostat knob by pulling straight out on the knob with a firm, steady pull.

The temperature adjusting screw is located in the middle of the thermostat shaft.

b. Insert a small-bladed flat-tipped screwdriver into the adjusting screw. Turn the adjusting

screw in ¼-turn increments to adjust the temperature. Turning the screw clockwise decreases the temperature; turning it counter-clockwise increases the temperature. DO NOT allow the thermostat shaft to turn while turning the adjusting screw.

c. Recheck the thermometer/pyrometer reading the next time the burner comes on. d. Repeat steps 6.b. through 6.c. until the thermometer/pyrometer reading remains within the

range 335-360°F (168-182°C) through several cycles. If calibration cannot be obtained for any reason, call a Factory Authorized Service Center for service.

e. Reinstall the thermostat knob.

7. Remove the thermometer or pyrometer.

1-11

DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7 Replacing Fryer Components

1.7.1 Replacing the Computer

1. Disconnect the fryer from the electrical

supply.

2. Unscrew the two computer panel screws.

The computer panel is hinged at the bottom and will swing open from the top.

3. Unplug the fryer wiring harness and ground

wire from the back of the computer.

4. Remove the computer by lifting it from the

hinge slots in the fryer control panel frame.

5. Reverse the procedure to install a new

computer.

Computer panel in “down” position.

Disconnect the 15-pin connector and ground wire (arrows) from the computer.

Control

anel frame with computer removed.

1-12

DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7.2 Replacing the Backup Thermostat (if applicable)

1. Disconnect the fryer from the electrical supply.

2. Drain cooking oil from frypot.

3. Remove thermostat knob.

4. Disconnect the wiring plug(s) from the component shield/control box.

5. Disconnect leads from terminal block.

6. Remove screws securing the thermostat bracket to fryer.

7. Follow Steps 5-7 in Section 1.7.4, Replacing the High-limit Thermostat, to remove thermostat

from frypot.

8. Remove the defective thermostat from the thermostat bracket and replace with a known good

thermostat. Use care not to damage the probe bulb and lead on the new thermostat.

9. Reverse the above steps to install the replacement.

CAUTION

The backup operating thermostat must be calibrated after installation is complete.

Refer to Section 1.6.2 for calibration instructions.

1-13

DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7.3 Replacing the Temperature Probe; Computer-equipped Fryers

1. Disconnect the fryer from the electrical supply.

2. Drain cooking oil from the frypot. Allow the

frypot to cool completely before proceeding.

3. Remove the fryer door for easier access to

the temperature probe. D models: Lift door up, disengage rod from lower door bracket, and remove door. CFD/SCFD/FPD models: Remove the top bracket and hinge, then remove door.

4. Disconnect the probe harness connector

(arrow). Use a pin pusher to remove plug from probe wires (probe side only). Retain the plug for re-assembly on new probe.

5. a. 1.5” drains: Remove drain extension from

elbow on drain valve. Set aside for reassembly. Drain extensions will vary in shape and size according to fryer model.

b. 3” drains:

- Remove the nuts holding the drain valve

straps onto the drain tube studs.

- Disconnect the Teflon tube at the back of

the T-shaped center tube piece.

Disconnect the two-pin probe harness connector (arrow). On units with 1.5” drains, remove the drain extension from the elbow on the drain v alve.

- Disconnect any other components

attached to the tubes.

- Carefully remove the tubes by pulling

down at an angle, straight out of the drain valves.

- Set aside for reassembly.

NOTE: Dean fryers may be equipped with either 1.5” or 3” drains. Follow the instructions appropriate for the drain type used.

On units with 3” drains, remove the nuts, Teflon tube (not pictured), clamp, boot, and drain t ubes. (Step 5.B)

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DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7.3 Replacing the Temperature Probe; Computer-equipped Fryers (cont.)

6. Remove the appropriate burners to gain

access to the temperature probe. (See Steps 20-22 on page 1-27 for more details.)

NOTE: Ensure that the burners are placed in their original spots when putting them back into the fryer. (See page 1-28.)

Remove burners to gain access to temperature probe.

7. Loosen and unscrew the compression nut

and the pass-through nut completely from the frypot. Proceed to the next step before removing the probe from the frypot.

8. Remove temperature probe mounting

hardware. Some older pots may use a spring-bracket combination. Newer pots use mounting clips. Retain mounting hardware for installation of new temperature probe.

Loosen and unscrew completely the compression nut (bottom arrow), then the pass-through nut (top arrow

Newer pots have mounting clips.

Older pots have spring-bracket combinations.

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DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7.3 Replacing the Temperature Probe; Computer-equipped Fryers (cont.)

9. The temperature probe can be removed

through the bottom of the frypot as follows: Ensure the two-pin connector has been removed from the probe wiring harness (step 4, above). Remove the harness insulation. The probe can be pulled through the frypot from the bottom (complete step 7, above, prior to removing probe).

10. Carefully remove the probe from the frypot. As

the probe is removed, tilt the probe at an angle to facilitate removal (curved probes only).

IMPORTANT: When installing new probe,

First remove the mounting clips holding the probe in place. Retain mounting hardware for installation of new

robe.

ensure probe is positioned properly with the mounting hardware installed prior to tightening the compression nut. Once tightened, the probe

cannot be repositioned.

Installing the New Temperature Probe:

1. Feed the probe wire through the probe nipple from the top side of the frypot.

2. Loosely install the bladder nut.

3. Mount the probe into the mounting hardware.

4. Tighten the bladder nut.

5. Install the insulation and plug.

1.7.4 Replacing the High-limit Thermostat

1. Turn fryer off and drain oil from the frypot. Allow the frypot to cool completely before

proceeding.

2. Perform steps 1-4 in Section 1.7.1, Replacing the Computer.

3. Re move the fryer door for easier access to the temperature probe. D models: Lift door up, disengage

rod from lower door bracket, and remove door. CFD/SCFD/FPD models: Remove the top bracket and hinge, then remove door.

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DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7.4 Replacing the High-limit Thermostat (cont.)

4. Remove two screws securing the high-limit

mounting-bracket. Do not disconnect wires from high-limit at this time.

5. Loosen and completely unscrew the compression

nut, then the pass-through nut on the frypot bottom. Proceed to the next step before removing high-limit from frypot.

6. Remove high-limit mounting hardware. Older pots

may use a spring-bracket combination. Newer pots will use mounting clips. Retain mounting hardware for installation of new high-limit.

Remove screws (arrows) securing high-limit to fryer.

Compression nut unscrewed. Unscrew the pass-through nut (arrow)

Older pots use spring-bracket combination.

Newer pots have mounting clips.

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DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7.4 Replacing the High-limit Thermostat (cont.)

7. Carefully pull high-limit capillary tube and bulb out

of the frypot from the bottom.

8. Mark and disconnect wires at the high-limit in the

component box.

Remove high-limit capillary tube and bulb from the bottom of the frypot.

1-18

Mark and disconnect high-limit wiring (arrows). Reconnect wires to the same terminals on the replacement high-limit.

DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7.4 Replacing the High-limit Thermostat (cont.)

9. Remove high-limit from fryer by pulling the

capillary tube and bulb through the component box opening (arrow). This may require removal of the control panel frame.

10. Reverse the above steps for high-limit installation.

IMPORTANT: When installing new high-limit or backup thermostat, ensure the capillary tube and bulb are positioned properly with the mounting hardware installed prior to tightening the compression nut. Once

tightened, the capillary tube cannot be repositioned.

Component box opening (arrow).

1.7.5 Replacing Rocker Switches

1. Disconnect the fryer from the electrical supply.

2. If the switches are located on front panel, remove the screws securing panel to fryer. Do not

allow the panel to hang on the switch wiring harness; use some type of support. (Figure A) If the switches are located in a control box within the fryer, remove the screws securing the switch panel to the control box. Do not allow the switch panel to hang from the switch wiring harness. (Figure B)

Remove screws.

Switch Guard

Pass the wires through the switch guard (if applicable) before connecting to switch.

FIGURE A

Remove the screws holding the plate in place, then depress the clips on each end to remove the switch.

FIGURE B

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DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7.5 Replacing Rocker Switches (cont.)

3. Depress the retaining clips (see illustration below) and push the switch out of the slot. If there is

a switch-guard present, retain it for installation of the replacement switch.

Depress clips on each side to remove switch from control panel.

4. Remove wires one at a time from the switch being removed and connect to the replacement

switch until all wires are transferred.

5. Reverse the above steps for reassembly.

1.7.6 Replacing the Gas Valve

DANGER Drain the frypot or remove the handle from the drain valve before proceeding further.

1. Disconnect fryer from electrical and gas supplies.

2. Disconnect the wires from the gas valve terminal block, marking each wire to facilitate

reconnections. For 120VAC gas valves, disconnect the black wire from the high-limit, then remove the bobtail connecting the white wire.

3. Remove the high-limit thermostat wire from the gas valve pilot coil (all but 120 VAC valves).

4. Remove the pilot gas line fitting from the gas valve.

5. Remove the pipe union collars to the left and right of the gas valve and remove the valve.

6. Remove the pipefitting from the old gas valve and install on the replacement valve, using Loctite

PST567 or equivalent pipe thread sealant on threads. Do not apply sealant to the first two pipe threads. Doing so will clog and damage the gas valve.

7. Reverse steps 1-5 to install the replacement gas valve.

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DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7.7 Replacing the Pilot Assembly

1. Remove the pilot tubing from the bottom of the pilot assembly.

2. If the pilot is an electronic ignition pilot, disconnect the ignition cable and the sense wire.

3. Remove the two pilot mounting screws from the pilot mounting bracket and remove the pilot.

4. Reverse the procedure to replace the pilot assembly.

NOTE: The above procedure is applicable to standing pilot, electronic ignition, and trailing pilot assemblies.

1.7.8 Replacing the Frypot

1. Open fryer doors and remove filter pan (if applicable). Ensure computer and all power switches

are off. Drain and dispose of or store oil from all frypots prior to moving fryer.

DANGER

Hot cooking oil will cause severe burns. Never attempt to move this appliance when

filled with hot cooking oil or to transfer hot cooking oil from one container to

another.

2. Turn gas valve off, then turn gas off at supply valve or meter. Disconnect supply line from gas

manifold at rear of fryer.

NOTE: If restraints are installed on the fryer, disconnect restraints prior to disconnecting the gas supply line.

3. Unplug fryer from electrical supply source.

4. Remove the fryer door for easier access to the temperature probe. D models: Lift door up,

disengage rod from lower door bracket, and remove door. CFD/SCFD/FPD models: Remove the top bracket and hinge, then remove door.

5. Remove basket hanger from flue cap by lifting up

and off of fryer. Some units may have a built-in flue deflector on the basket hanger. Units with basket lifts will require the removal of the lift arms prior to removing the basket hanger.

1-21

Removing the flue cap.

DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7.8 Replacing the Frypot (cont.)

6. Carefully pry the capping strip off with a screwdriver

or similar tool and set aside. Be careful not to bend the capping strip during removal.

Removing capping strip.

7. Locate all screws securing back panels. Screw location and orientation will vary according to

fryer model.

Typical screw locations on the back

8. Remove back panels on fryer. Retain screws for re-

assembly.

9. Remove screw securing brace (and back panel) to flue

cap. Support brace with hand while removing screw to prevent brace from falling away. Remove brace and set aside for reassembly.

1-22

Removing brace holding back panel to flue cap.

DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7.8 Replacing the Frypot (cont.)

10. Remove screws securing flue-cap braces to frypot

(a nut-driver with an extension or long screwdriver is required). Use care not to drop the screws into the flues. If this happens, the screws can be retrieved when the flue is removed (Step

16). Use a screwdriver or similar tool to free flue cap from frypots. Remove flue cap by lifting up and off of fryer.

11. Remove gas manifold pipe for access to gas

manifold shield by disconnecting at the unions. Ensure gas supply is shut off and supply line is disconnected prior to removing. Set gas manifold aside. Remove screws securing gas manifold shield. Remove shield to access oil-return plumbing components connected to the frypots.

NOTE: For units without built-in filtration skip the steps pertaining to removal and replacement of oil-return plumbing.

12. Remove cotter-pin from oil-return actuator rod.

Observe washer placement prior to removing rod from the valve actuator (arrows). Disconnect actuator rod and remove washers. Set washers aside for later re-assembly.

Removing flue cap.

Removing gas manifold shield.

Disconnecting oil-return linkage from valve.

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DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7.8 Replacing the Frypot (cont.)

13. Remove steel line from oil-return valve and

nipple by loosening flare fittings on both ends. Hold backup with an adjustable wrench when removing fittings.

(Prior to removal, absorbent cloth or paper

towels should be placed under the oil line to catch any oil remaining in the lines.)

14. Unscrew both flare fittings completely prior to

line removal. Remove oil-return line and set aside (see Step 15 if line does not disengage easily).

15. Turning the oil-return valve slightly outward

with a pipe wrench or similar tool will facilitate return-line removal.

16. Remove four bolts securing flue to the frypot

being removed. Remove the flue by sliding back and away until clear of frypot. Retrieve any screws dropped into the flue during removal of the flue cap and frypot bracket.

17. Remove oil-return valve from frypot (see Step

15, above, for more information). Turn the valve assembly counter-clockwise to remove. If nipple remains in frypot, remove it also. Set aside for reassembly. (Skip to 19B if unit has 3” round drains.)

Holding backup while unscrewing flare nut on oil-return line.

Remove oil-return line after disconnecting flare nuts.

Turn the oil-return valve slightly outward to facilitate removal of the oil-return line.

Removing bolts (arrows) securing flue to frypot.

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DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.7.8 Replacing the Frypot (cont.)

18. If fryer is equipped with a front drain manifold,

disconnect manifold at slip-nut fitting and remove.

19. a. 1.5” drains:

- Remove drain extension from elbow on

drain valve. Drain extensions will vary in shape and size according to fryer model.

- Set aside for reassembly.

b. 3” drains: Only tubes directly blocking the frypot being replaced need to be removed.

- Remove the nuts holding the drain valve

straps onto the drain tube studs.

- Disconnect the Teflon tube at the back of

the center dump tube piece.

- Disconnect any other components attached

to the tubes.

- Remove the clamps and rubber boots

holding the drain sections together by loosening the nuts on each clamp.

Carefully remove the tubes by pulling

down at an angle, straight out of the drain valves.

- Set aside for reassembly.

On front drain manifolds, disconnect the slip-nut fitting (arrow) to remove.

Removing 1.5” drain extension. (Step 19.A)

Removing 3” drain tubes. (Step 19.B)

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