Dean D80 Series Specifications
Contents
1. DESCRIPTION Lighted Display left display of various functions and operations Lighted Display right display of various functions and operations Program Lock and Temperature Check Switch locks program in computer and or displays frypot temperature when depressed Old style computers will have this switch O Power Switches either switch turns power ON or OFF Old style computers will have this switch gt Product and Coding Switches provides access to computer and programming functions Old style computers will have these 1m 2m 3m 4m 5m 6m 7m 8 9 Om Rm switches Programming Switch used when reprogramming the computer memory Old style computers will have this switch Cong WARNING Before turning on computer ensure the fryer is filled with cooking oil shortening or water NEVER allow water to enter the Filtration System if applicable 5 1 5 1 Operating Fryers with Dean Compu Fry Computers cont 5 1 1 Equipment Setup and Shutdown Procedures2. Com seindwog 80 10 9 2 295 dumy 10120uu05 F we EEN TO gt um Pedwo i us zr EET einesedue 1216 pilos 49114 epesseg M Ve 409 DVAOZE Lua mes 3 qua medias 40 99UU0D 2 2 KS Y E t na E
3. 18 SELP will appear in the left display If you desire to program more products return to Step 5 If no more programming is required lock in program by pressing the switch 5 2 1 Boil Feature A CAUTION Do not drain water or boil out solution into the filtration system if applicable Irreparable damage will result and void the warranty 1 Before switching the fryer ON close the frypot drain valve Fill empty frypot with mixture of cold water and detergent Follow detergent instructions when mixing NOTE Boil Mode will not turn on both sides of computer Each side will have to be turned on separately 2 To program computer for Boil Feature press either D 3 Press the Z switch switch CogE will appear in the left display 101 6t 5L 30 4 Enter remain there until either 1 6 5 3 in that sequence The right display will read 6 oi The temperature is automatically set for 195 F 91 C The fryer will attain this temperature and 0 switch is pressed which cancels the boil out mode In high altitude locations constantly monitor the fryer for over boil con
4. 1 BC 5 DCH Press Q OI O IO 1 6 5 0 in that sequence to enter the program mode 5 P Setpoint will appear in the left display This is for setting the cooking temperature The temperature previously selected will be displayed in the right display Enter new temperature Press the switch to lock in temperature setting If the setting is correct press the switch to cancel the selection SELP Select Product will appear in the left display Press the product button to be programmed SENS will appear in the left display The sensitivity number previously selected will be displayed in the right display Enter the new desired sensitivity number the range is to 9 Enter 0 for no sensitivity Press the switch to lock in the setting Sensitivity adjusts computer cooking time to compensate for the drop in cooking oil shortening temperature when a basket of product is placed into the fryer Sensitivity decreases or increases cooking time to counterbalance variances in product density basket load size and initial temperature A proper sensitivity setting will ensure a high quality product For example 4 ounces of fries can be programmed to cook to the sam
5. 10 SELP will appear in the left display If you desire to program more products return to Step 5 If no more programming is required lock in program by pressing the switch 11 5 P Setpoint will appear in the left display This is for setting the cooking temperature The temperature previously selected will be displayed in the right display Enter new temperature Press the switch to lock in temperature setting If you do not wish to change the setting press the switch 12 SELP Select Product will appear in the left display Press the product button to be programmed 13 5Ef15 will appear in the left display The sensitivity number previously selected will be displayed in the right display Enter the new desired sensitivity number the range is 1 to 9 Enter 0 for no sensitivity Press the Y switch to lock in the setting Sensitivity adjusts computer cooking time to compensate for the drop in cooking oil shortening temperature when a basket of product is placed into the fryer Sensitivity decreases or increases cooking time to counterbalance variances in product density basket load size and initial temperature A proper sensitivity setting will ensure a high quality product For example 4 ounces of french fries can be programmed to cook to the same quality as 2 p
6. High Limit Reset Switch located under Filter Reset Switch 7 Amp Circuit Boil Out Switch operates only in Thermatron mode When each individual control panel This Breaker this switch is inline between ON this switch bypasses the Thermatron melt cycle and Switch must be manually reset if fryer the filter pump and the Filter Power allows the water temperature to reach 196 F exceeds high limit setpoint Switch Ensure Filter Power Switch is OFF before resetting or replacing Many Decathlon fryers use solid state temperature controller or Thermatron controller instead of a computer or basic thermostat A Thermatron system incorporates a temperature control circuit board a potentiometer and a temperature probe This system is more accurate and more reliable than a standard thermostat and less expensive than a computer controller Thermatron systems are operated with the 77 following controls Thermatron Temperature Controller os Angeles Calif MAIN POWER SWITCH connects disconnects primary power double lighted with center position OFF One main switch controls two Thermatron controllers and or two back up thermostats When the Main Power Switch is in the center position power is removed from the two fryers controlled by the Thermatron controllers or back up thermostats When the Main Power Switch pressed to the right power is supplied to the Thermatron of each fryer When pressed to the left power is su
7. 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 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 ro
8. enue N eoueueijure N 9 uorejeisu SIDAI Ser uo ueooq D20 D50 D60 amp D80 Series Bam DEAN Dean a member of the Commercial Food Equipment Service Association recommends using CFESA Certified Technicians Price 8 00 819 5698 10 00 24 Hour Service Hotline 1 800 551 8633 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 A CAUTION Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other cooking appliance A 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 A 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 A WARNING Safe and satisfactory operation of your equipment depends on proper installation Installation MUST conform with local codes or in absence of local
9. 3 6 1 2 Adjustments to Different Gas Types Gases and Gas Supply G20 G25 G31 Pressure 20 mbar 25 mbar 37 50 mbar Burner Marking blue marking blue marking red marking Pilot Marking TJ024 TJ024 2 Gas pressure at the 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 flame volume 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 lt gas family mbar gt to the rating plate Remove any reference to the previously used g
10. einpoyy 18414 g gt g HM 5 2 wg 5 2 y 7 5 7 4 3 Decathlon Interface Board Enlarged View OL ER 2 pno7 L jeuiuua L peog punog er 5 LON 1545 9QAZI 19 15 78 aasn LON LSdS 218 15 V3H H dial 1H9IH A971 1 v zr dial 1331 49V110A 7 6 7 4 4 Decathlon D 50G and D 60G CE Only 31dnoooWuaHL 0213 NOLLO3NNOO uaqios HOLINOI OZ3ld CZ ie A1awassv T HOLO3NNOO 3A1VA OL 093 HOLdVQV JAYA ZH 0gr 41 OWA ve SVD 189 9 svo ivN SVO 929 029 YATIOWLNOO SYNLVYHAdWAL ALVLS CMOS 09 Ave LV LSOWYSHL LIIAFT HOIH 1050 aunyesodwia L 0 1 HOLIMS AL343VS NIVHG 6 9 1 1 1 1 4 1 LNONOE IWNOILdO D eden E HOLIMSH3MOd Alddns H3MO
11. Simmer the solution for approximately 45 minutes Wearing protective gloves scrub the sides of the fry vessel and the tubes with the L shaped teflon brush being careful not to disturb the temperature sensing probes and the high limit thermostat Do not allow the water level to decrease below the bottom OIL LEVEL line in fry vessel during boil out operation After boil out is complete turn the thermostat dial to OFF and drain the solution from the fry vessel Place a metal pan or bucket under the drain port to collect the water from the fry vessel Close the drain add fresh water without boil out solution and wash all surfaces of the fry vessel Drain again Refill the fry vessel with fresh water and vinegar to neutralize any residual boil out solution Wash all surfaces of the fry vessel Drain completely and wipe down all surfaces of the fry vessel to completely eliminate water from the vessel 4 3 4 2 2 Filtration Boil Mode Option Equipped Fryers A Pour cleaning solution into the fry vessel and add water to the bottom OIL LEVEL line scribed in the back of the fry vessel B Turn fryer power switch ON Then press the fryer reset switch A CAUTION If the pilot and main burner go out the fryer s MUST be left completely shut down at least 5 minutes before lighting C Turn the boil out switch ON The main burner will ignite DO NOT LEAVE THE FRYER UNATTENDED DURING THE BOIL OUT PROCEDURE A CAUTION Do no
12. 0001 2 14 0001 3 14 0590 2254 2729 1143 1910 2651 2652 36 0012 24 0350 50 0041 1 50 004 1 2 50 0001 1 Orifice Nat Gas G 20 25 Blue CE ONLY Orifice LP Gas G 31 37 50 Red CE ONLY Pilot Assembly For Natural Gas Pilot Assembly For LP Gas Pilot Assembly Nat Gas G 20 25 CE ONLY Pilot Assembly LP Gas G 31 37 50 CE ONLY Manifold Support Bracket Diffuser Assembly Drain Valve Burner Left Side Burner Center Burner Right Side Heat Shield Gas Valve Natural Gas Electronic Ignition 24 VAC Gas Valve LP Gas Electronic Ignition 24 VAC Gas Valve Natural Gas 120 VAC Gas Valve LP Gas 120 VAC Gas Valve Natural Gas G 20 25 24 VAC CE ONLY Gas Valve LP Gas G 31 37 50 24 VAC CE ONLY Channel Lower Hinge Bracket Side Panel Left Side Side Panel Right Side Wireway Control Panel 8 3 8 2 Decathlon D 50 Primary Components cont ITEM PART COMPONENT 18 50 0132 Control Panel 19 2025 Switch Rocker Yellow Lens 125 250VAC 2674 Switch Rocker Green Lens 125 250 VAC CE ONLY 20 50 0127 1 Canopy 21 12157 Flue Box Assembly 22 36005 2 Vessel Upper Rear 23 50005 Door Assembly 24 2608 Fry Basket 25 14 0179 Grid Assembly 26 36 0026 2 Basket Hanger 27 1943 Caster 5 inch w o Brake 28 1942 Caster 5 inch with Brake 29 44 1363 Extended Drain Nipple 30 24159 Power Cord 31 11 0140 2 Cover Outlet Duct 32 50 0050 Rear Panel Structural Back 7 N A Upper Structural Back
13. Fry Computers 1 To program constant temperature display press the 0 switch 2 Press the switch CogE will appear in the left display 1 60 SCH LC 3 Enter O 6 5 L in that sequence The cooking oil shortening temperature will display constantly in the right display on a full pot and in both displays on a split pot NOTE During the product cooking process the cooking time will not be displayed but timing will be taking place 4 To remove the constant oil temperature display and display the cooking time repeat Step 2 and Step 3 5 7 5 3 Operating Fryers with Thermatron Controllers Fryer Power Switch controls power to each Filter Power Switch connects Main Power Switch connects disconnects primary power double individual fryer both in Thermatron or disconnects power to filter pump Fryer lighted with center position OFF This switch controls two Back up mode Power Switch should be OFF when Thermatron controllers and or two back up thermostats filter is in use i ON OFF ON i ON OFF ON o o F 9 F 9 M F F T BOIL OUT MAIN POWER BOIL OUT B MAIN POWER o 6 gt 9 9 N N E N FILTER LS H
14. Left Side 16 60 0021 2 Side Panel Right Side L7 60 0001 1 Wireway Control Panel 18 60 0005 2 Control Panel 19 2025 Switch Rocker Yellow Lens 125 250V AC 2674 Switch Rocker Green Lens 125 250 VAC CE ONLY 20 60 0006 1 Canopy 21 18065 Flue Box Assembly 22 60044 2 Vessel Upper Rear 23 60005 Door Assembly 24 2609 Fry Basket 25 18012 SC Grid Assembly 26 18 0067 Basket Hanger 27 1943 Caster 5 inch w o Brake 28 1942 Caster 5 inch with Brake 29 44 1363 Extended Drain Nipple 30 24159 Power Cord 31 11 0140 2 Cover Outlet Duct 32 N A Rear Panel Structural Back 60 0050 Upper Structural Back 18 0023 1 Lower Structural Back 33 1731 2 Leg Black 34 12085 Leg Support Assembly 35 18 0096 Burner Mounting Bracket 8 5 8 4 Decathlon D 80 Primary Components ITEM PART COMPONENT 80018 1 Vessel Weld Assembly M S 80018 2 Vessel Weld Assembly S S 20092 1 Vessel Weld Assembly M S CE ONLY 20092 2 Vessel Weld Assembly S S CE ONLY 18131 Gas Manifold Weld Assembly 14 0067 4 Orifice Natural Gas 14 0067 5 Orifice LP Gas x X zb zz EWN zz Sr Q2 b2 P2 L2 H E GO AJ D GJ tA 14 0067 10Blu 14 0067 2Red 14199 1 14199 2 14199 1 14199 2CE 14 0402 20010 1 2066 14 0001 1 14 0001 2 14 0001 3 80 0069 2254 2729 1143 1910 2651 2652 20 0121 24 0350 80 004 1 1 80 004 1 2 80 0001 1 80 00
15. are installed must be level Front View Rear Side View i Optional Caster j Optional Caster i Rear Only Front Only 1 4 20 x 3 4 Hex Bolt Y Front Channel or gt T CN Rear Channel m H Leg Support Assembly pee o _ i SCH Washer i i 9 Hex Head Locknut x 1 4 20 x 3 4 Hex Bolt Front or Rear Leg with Mounting Plate LT Pod Wen x Pod Front Caster 5 Swivel Rear Caster 5 Rigid Lo w Brake EE Front Channel 7 or Rear Channel 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 Appliance Countries Supply Pressures and Appliance Gas SS E Categories Gas Categories Belgium GR Greece 37 and 50 020 625 20 25 ES Spain 2 LU Luxembourg 2 37 50 G20 G25 20 25 FR Fra
16. burners outlet gas pressure in inches WC and whether the unit has natural or propane gas orifices A 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 A CAUTION Local building codes usually prohibit a fryer with its open tank of hot oil from being installed beside an open fl
17. 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 A 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 A 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 1 2 3 4 5 6 7 8 DEAN Decathlon Series Gas Fryers TABLE OF CONTENTS INTRODUCTION PREVENTATIVE MAINTENANCE TROUBLESHOOTING PARTS LIST 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 factor
18. ii N A Lower Structural Back 33 1731 2 Leg Black 34 12085 Leg Support Assembly 35 14 0585 Burner Mounting Bracket 8 3 Decathlon D 60 Primary Components ITEM PART COMPONENT 1 60043 1 Vessel Weld Assembly M S 60043 2 Vessel Weld Assembly S S 60050 1 Vessel Weld Assembly M S CE ONLY 60050 2 Vessel Weld Assembly S S CE ONLY 2 18131 Gas Manifold Weld Assembly 3 14 0067 1 Orifice Natural Gas 14 0067 2 Orifice LP Gas 14 0067 10Blu Orifice Nat Gas G 20 25 Blue ONLY S 14 0067 2Red Orifice LP Gas G 31 37 50 Red ONLY 4 14199 1 Pilot Assembly For Natural Gas D 14199 2 Pilot Assembly For LP Gas 14199 1 Pilot Assembly Nat Gas G 20 25 CE ONLY 14199 2CE Pilot Assembly LP Gas G 31 37 50 CE ONLY 5 14 0402 Manifold Support Bracket 6 18063 1 Diffuser Assembly 7 2066 Drain Valve 8 14 0001 1 Burner Left Side 8 4 8 3 Decathlon D 60 Primary Components cont ITEM PART COMPONENT 9 14 0001 2 Burner Center 10 14 0001 3 Burner Right Side 11 60 0075 Heat Shield 12 2254 Gas Valve Natural Gas Electronic Ignition 24 VAC 2729 Gas Valve LP Gas Electronic Ignition 24 VAC 1143 Gas Valve Natural Gas 120 VAC 1910 Gas Valve LP Gas 120 VAC 2651 Gas Valve Natural Gas G 20 25 24 VAC CE ONLY 2652 Gas Valve LP Gas G 31 37 50 24 VAC CE ONLY 13 60 0007 1 Channel 14 24 0350 Lower Hinge Bracket 15 60 0021 1 Side Panel
19. 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 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 Le E G20 2 40 42 14 0067 10Blu 2 BLUE 10 4 0 20MBAR 14199 1CE D20G 15 G25 2 40 42 14 0067 10Blu 2 BLUE 15 6 0 25MBAR 14199 1CE G31 1 51 53 14 0067 2Red 2 RED 27 10 8 37MBAR 14199 2CE G20 2 40 42 14 0067 10Blu 4 BLUE 10 4 0 20MBAR 14199 1CE D50G 30 G25 2 40 42 14 0067 10Blu 4 BLUE 15 6 0 25MBAR 14199 1CE G31 1 51 53 14 0067 2Red 4 RED 27 10 8 37MBAR 14199 2CE G20 2 40 42 14 0067 10Blu 5 BLUE 10 4 0 20MBAR 14199 1CE D60G 37 5 G25 2 40 42 14 0067 10Blu 5 BLUE 15 6 0 25MBAR 14199 1CE G31 1 51 53 14 0067 2Red 5 RED 27 10 8 37MBAR 14199 2CE G20 2 40 42 14 0067 10Blu 5 BLUE 10 4 0 20MBAR 14199 1CE D80G 37 5 G25 2 40 42 14 0067 10Blu 5 BLUE 15 6 0 25MBAR 14199 1CE G31 1 51 53 14 0067 2Red 5 RED 27 10 8 37MBAR 14199 2CE 3 6
20. 05 2 2025 2674 80 0006 1 20053 80020 2 80005 1 2609 20000 SC 18 0067 1943 1942 44 1363 24159 Orifice Nat Gas G 20 25 Blue CE ONLY Orifice LP Gas G 31 37 50 Red CE ONLY Pilot Assembly For Natural Gas Pilot Assembly For LP Gas Pilot Assembly Nat Gas G 20 25 CE ONLY Pilot Assembly LP Gas G 31 37 50 CE ONLY Manifold Support Bracket Diffuser Assembly Drain Valve Burner Left Side Burner Center Burner Right Side Heat Shield Gas Valve Natural Gas Electronic Ignition 24 VAC Gas Valve LP Gas Electronic Ignition 24 VAC Gas Valve Natural Gas 120 VAC Gas Valve LP Gas 120 VAC Gas Valve Natural Gas G 20 25 24 VAC CE ONLY Gas Valve LP Gas G 31 37 50 24 VAC CE ONLY Channel Lower Hinge Bracket Side Panel Left Side Side Panel Right Side Wireway Control Panel Control Panel Switch Rocker Yellow Lens 125 250VAC Switch Rocker Green Lens 125 250 VAC CE ONLY Canopy Flue Box Assembly Vessel Upper Rear Door Assembly Fry Basket Grid Assembly Basket Hanger Caster 5 inch w o Brake Caster 5 inch with Brake Extended Drain Nipple Power Cord 8 6 8 4 Decathlon D 80 Primary Components cont ITEM PART COMPONENT 31 11 0140 2 Cover Outlet Duct 32 80 0050 Rear Panel Structural Back E N A Upper Structural Back N A Lower Structural Back 33 1731 2 Leg Black 34 12085 Leg Support Assembly 35 18 0072 Burner Mounting Bracket 8 5 Opt
21. 9 3 7 Electrical Connections The fryer when installed must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 latest edition A WARNING This fryer is equipped with a three prong grounding plug for protection against shock hazard It should be plugged directly into a properly grounded three prong receptacle DO NOT CUT REMOVE OR OTHERWISE BYPASS THE GROUNDING PRONG ON THIS PLUG The rating plate and wiring diagram are located inside the front door The fryer is equipped with a 120VAC single phase 60 hertz system Domestic or 230VAC single phase 50 hertz system International CE Do not cut or remove the ground prong from the power cord plug Do not attempt to use the fryer during a power outage 3 10 DECATHLON SERIES GAS FRYERS CHAPTER 4 FRYER OPERATIONS 4 1 Initial Start up A Cleaning New units are wiped clean with solvents at the factory to remove any visible signs of dirt oil grease etc remaining from the manufacturing process then coated lightly with oil Before any food preparation wash thoroughly with hot soapy water to remove any film residue and dust or debris then rinse out and wipe dry Also wash any accessories shipped with the unit Close the drain valve completely and remove the crumb screen covering the heating tubes Make sure the screws holding the thermostat and high limit control sensing bulbs into the ves
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23. ES GAS FRYERS CHAPTER 6 PREVENTATIVE MAINTENANCE 6 1 General Any equipment works better and lasts longer when maintained properly and kept clean Cooking equipment is no exception Your Decathlon fryer should be kept clean during the working day and thoroughly cleaned at the end of each day Below are recommendations for daily weekly and periodic preventative maintenance 6 1 1 Daily A Remove and wash all removable parts B Clean all exterior surfaces of the cabinet Do not use cleaners steel wool or any other abrasive material on stainless steel C Filter the cooking oil and replace if necessary The oil should be filtered more frequently when under heavy use 6 1 2 Weekly A Completely drain the oil from the fryer into a suitable container for disposal Do not use a glass or plastic container B Clean the fry vessel by following boil out procedures in Chapter 4 2 A CAUTION Never allow water to boil down and expose the heating tubes Fry vessel damage will result 6 1 3 Periodic The fryer should be inspected and adjusted periodically by qualified service personnel as part of a regular kitchen maintenance program 6 1 6 1 4 Stainless Steel Care A WARNING DO NOT let water splash into the tank of hot oil It will splatter and can cause severe burns All stainless steel fryer cabinet parts should be wiped regularly with hot soapy water during the day and with a l
24. F 4 Wait approximately 5 minutes for accumulated gas to disperse 4 1 4 1 1 Pilot Lighting Procedures Standing Pilot Only cont Note Inspect high limit thermostat temperature probe location prior to filling fry vessel with water or oil Ensure that connecting hardware is intact and bulbs are properly attached 5 Fill the fry vessel with oil or water to the bottom OIL LEVEL line scribed on the vessel back Ensure that heating tubes are covered in liquid prior to engaging burners 6 Open the manual shut off valve on the incoming service line 7 Apply lighted match or taper to the pilot burner head 8 Turn the gas cock dial on the control valve to Pilot then depress and hold the dial until the pilot stays lit approximately 1 minute 9 If the pilot fails to stay lit depress the dial and re light the pilot depressing the dial longer before releasing 10 When the pilot stays lit turn the gas cock dial to 11 Turn the operating thermostat computer or controller on then ensure the main burners ignite from the pilot A WARNING When checking for burner ignition or performance do not get too close to the burners Slow ignition can cause possible flashback increasing the potential for facial and body burns 4 1 2 Pilot Lighting Procedures Electronic Ignition Systems A WARNING Never use a match or taper to light pilot on this ignition system 1 Turn gas ON 2 Turn electric power ON
25. Ignition 24 VAC Gas Valve LP Gas Electronic Ignition 24 VAC Gas Valve Natural Gas 120 VAC Gas Valve LP Gas 120 VAC Gas Valve Natural Gas G 20 25 24 VAC CE ONLY Gas Valve LP Gas G 31 37 50 24 VAC CE ONLY Channel Lower Hinge Bracket Side Panel Left Side Side Panel Right Side Wireway Control Panel Control Panel Switch Rocker Yellow Lens 125 250VAC Switch Rocker Green Lens 125 250 VAC CE ONLY Canopy Flue Box Assembly Vessel Upper Rear Door Assembly Fry Basket Grid Assembly Basket Hanger Caster 5 inch w o Brake Caster 5 inch with Brake Extended Drain Nipple Power Cord 8 2 8 1 Decathlon D 20 Primary Components cont ITEM PART COMPONENT 31 11 0140 2 Cover Outlet Duct 32 Rear Panel Structural Back 07 0139 Upper Structural Back ii 07 0140 Lower Structural Back 33 1731 2 Leg Black 34 14169 Leg Support Assembly 35 07 0006 Burner Mounting Bracket 8 2 Decathlon D 50 Primary Components ITEM PART COMPONENT 14907 1 Vessel Weld Assembly M S 14907 2 Vessel Weld Assembly S S 14948 1 Vessel Weld Assembly M S CE ONLY 14948 2 Vessel Weld Assembly S S CE ONLY 14130 Gas Manifold Weld Assembly 14 0067 13 Orifice Natural Gas 14 0067 2 Orifice LP Gas Z vn OS LOU x X EHR KE EWN zz Sr I Au 4 14 0067 10Blu 14 0067 2Red 14199 1 14199 2 14199 1CE 14199 2CE 14 0402 14778 2066 14 0001 1 14
26. Setup WARNING Fill the frypot to the bottom OIL LEVEL line with vegetable oil before pressing the ON OFF switch O to the ON position Failure to do so could damage the frypot Fill the frypot with vegetable oil to the bottom OIL LEVEL line located on the rear of the frypot This will allow for oil expansion as heat is applied Do not fill cold oil any higher than the bottom line overflow may occur as heat expands the oil If solid shortening is used pack solid shortening into the cool zone of the frypot Continue to pack shortening in frypot to the bottom OIL LEVEL line Ensure that the power cord s is are plugged into the appropriate receptacle s Verify that the face of the plug is flush with the outlet plate with no portion of the prongs visible Ensure that the vegetable oil level is at the top OIL LEVEL line when the vegetable oil is af its programmed cooking temperature It may be necessary to add vegetable oil to bring the level up to the proper mark after the oil has reached the programmed cooking temperature If solid shortening is used the MELT cycle MUST be used to melt the shortening It may be necessary to add solid shortening to bring the level up to the proper mark after the packed shortening has melted DO NOT DISABLE OR CANCEL THE MELT CYCLE UNTIL ALL SOLID SHORTENING HAS MELTED Shutdown 1 Press the ON OFF switch to the OFF
27. ame of any type whether a broiler or the open burner of a range C Installation Standards 1 US installations must meet 2 Canadian installations must meet American National Standard Institute ANSI 783 11 American Gas Association 8501 E Pleasant Valley Road Cleveland OH 44131 National Electrical Code ANSI NFPA 70 American National Standard Institute 1430 Broadway New York NY 10018 NFPA Standards 96 and 211 National Fire Protection Association 470 Atlantic Avenue Boston MA 02110 CAN 1 B149 Installation Codes Canadian Gas Association 55 Scarsdale Road Don Mills ONT M3B 2R3 Canadian Electric Code 22 1 part 1 Canadian Standards Association 178 Rexdale Blvd Rexdale ONT M9W 1R3 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 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 B Do not connect this fryer to an exhaust duct Correct installation and adjustment will ensure adequate airflow to the fryer system 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 a
28. as 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 3 7 3 6 2 Gas Conversion Procedures cont Conversion from one gas family to another i e changing from natural gas to propane requires special components Obtain the necessary components using the cross reference tables on page 3 9 Conversions can only be executed by qualified factory authorized personnel Pilot flow adjustment Thermocouple connection Vent tube connection Pressure flow adjustment OFF Button ON Button Pilot Gas flow CE Gas Valve Pilot pressure adjustment Pressure flow adjustment remove cover screw to access remove cover screw to access Regulator Vent Pilot gas supply connection ON OFF Gas Cock Knob Non CE Gas Valve 3 8 3 6 2 Gas Conversion Procedures cont Use the following component information to convert from natural gas to propane and vice versa Decathlon Series Natural Gas to Propane Conversion Components Burner orifice 14 0067 2Red diameter 1 51 mm Appareil r gl pour G31 37 Fryer equipped for G31 37 Decathlon Series Propane to Natural Gas Conversion Components DESCRIPTION DE Burner orifice diameter 2 40 mm Appareil r gl pour G20 20 Fryer equipped for G25 25 3
29. bly RTD Temperature Dean Computer 13 12 0400 Thermocouple Pilot Bracket 14 2723 Thermopile Bracket 15 227158 Piezo Ignitor 44 1128 Piezo Bracket 16 1905 Transformer Honeywell 120 24 VAC 2518 Transformer 120 12 VAC 2137 Transformer 120 24 VAC S 2658 Transformer Dual CE CE ONLY 807 1999 17 2687 Thermostat High limit 18 1330 Fuse Holder 2747 Fuse Holder Slot head Safety ONLY 1331 Fuse 2A Slow Blow 19 2445 Interface Board Dean Computer Only 2442 G0 P C Board 24 VAC 14701 2 GO P C Board 120 VAC 2337 1 GO P C Board 208 240 VAC 20 2517 Relay 12 VDC 1PDT 21 2138 Relay 24 VAC 4PDT Not Illustrated 8 8 Dean 8700 Line Avenue Shreveport Louisiana 71135 TEL 1 318 865 1711 FAX Parts 1 318 219 7140 Tech Support 1 318 219 7135 SERVICE HOTLINE PRINTED IN THE UNITED STATES 1 800 551 8633 1
30. d c OWA 022 3snd 7 7 DECATHLON SERIES GAS FRYERS CHAPTER 8 PARTS LIST Controllers probes and related optional components are listed in Optional Components Controllers and Related Components Section 8 5 8 1 8 1 Decathlon D 20 Primary Components ITEM PART COMPONENT 07002 3 Vessel Weld Assembly M S 07002 4 Vessel Weld Assembly S S 07148 3 Vessel Weld Assembly M S CE ONLY 07148 4 Vessel Weld Assembly S S CE ONLY 07008 Gas Manifold Weld Assembly 14 0067 6 Orifice Natural Gas 14 0067 7 Orifice LP Gas x X zb zz EWN zz Sr Q2 b2 P2 L2 H E GO AJ D GJ tA 14 0067 10Blu 14 0067 2Red 07018 1 07018 2 14199 1CE 14199 2CE 14 0402 14154 2066 14 0001 1 N A 14 0001 3 07 0044 2254 2729 1143 1910 2651 2652 07 0213 24 0350 44 0981 1 44 0981 2 07 0224 07 0132 2 2025 2674 07 0060 07001 07 0004 07141 2608 07011 07 0212 1943 1942 44 1363 24159 Orifice Nat Gas G 20 25 Blue CE ONLY Orifice LP Gas G 31 37 50 Red CE ONLY Pilot Assembly For Natural Gas Pilot Assembly For LP Gas Pilot Assembly Nat Gas G 20 25 CE ONLY Pilot Assembly LP Gas G 31 37 50 CE ONLY Manifold Support Bracket Diffuser Assembly Drain Valve Burner Left Side Burner Center Burner Right Side Heat Shield Gas Valve Natural Gas Electronic
31. diately 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 After hook up bleed the gas line of air to ensure that the pilot light will ignite quickly 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
32. ditions If over boil occurs turn off fryer immediately allow to cool and re enter boil out mode to continue the boil out operation SEE CHAPTER 4 2 FOR ADDITIONAL BOIL OUT PROCEDURES 5 6 5 2 2 Fryer Recovery Time Check 1 check recovery time press the Y switch will appear in the left display 10 60 SCH 20 2 Enter O 0 O O 6 5 2 in that sequence The recovery time will appear in both displays for 5 seconds 5 2 3 Temperature Selection Fahrenheit to Celsius Not Applicable to Old Style Compu Fry Computers 1 To change the computer temperature from Fahrenheit to Celsius or Celsius to Fahrenheit press either switch 2 Press switch CogE will appear in the left display 10 60 807 3 Enter 0 1 6 5 8 in that sequence The computer will automatically convert the temperature from Fahrenheit to Celsius or Celsius to Fahrenheit 4 Press the 4 switch to display the temperature in the newly selected mode 5 2 4 Constant Oil Temperature Display Mode Not Applicable to Old Style Compu
33. e quality as 2 pounds A good initial setting is 4 or 5 Some experimenting with the range of 1 to 9 may be required to achieve optimum quality 5 2 Programming The Dean Compu Fry Computer cont 7 CO BC will now appear in the left display A previously entered cook time will appear in the right display If that time is correct press the switch If you wish to change the time enter the desired time in minutes and seconds The new time will be displayed in the left display Press the switch to lock in the setting 8 5 H now appears in the left display The previous shake time if any will appear in the right display If a product requires shaking during the cooking process set the shake time by pressing the number of minutes to cook before shaking Press the switch to lock in the time If no shake time is required press 0 and press the switch Example Total cook time 3 00 minutes shake after cooking 1 00 minute At the end of 1 00 minute a beeper will sound and the product button indicator will flash for three seconds 9 Hd will now appear in the left display Set the time to hold the cooked product from 13 seconds to 60 minutes Press the switch If you do not wish to use the hold time enter 0 and press the switch
34. ersion thermometer 4 3 2 Filling Fryer with Cooking Oil Shortening Computer A Fill the fryer as described in Filling Fryer with Cooking Oil Shortening Operating Thermostat Thermatron section B For solid shortening follow procedure in Section 4 3 1 Step Press the computer on off switch to ON The burners will initially operate in the MELT CYCLE mode until the shortening reaches 180 F It will then automatically switch to normal operation C When the fry vessel is filled and the shortening is melted carefully replace the crumb screen over the heat tubes Wear oil proof insulated gloves to avoid the potential for burn injury when replacing crumb screen D Before starting operation program the computer to the probable working temperature and wait for the temperature to stabilize WARNING Do not go near the area directly over the flue outlet while the fryer is operating Always wear oil proof insulated gloves when working with the fryer filled with hot oil Always drain hot oil into a metal container Hot oil can melt plastic buckets and crack glass containers See Filtration Manual for filtering procedures where applicable 4 6 DECATHLON SERIES GAS FRYERS CHAPTER 5 COMPU FRY THERMATRON INSTRUCTIONS 5 1 Operating Fryers with Dean Compu Fry Computers
35. heck that thermocouple lead is properly screwed into thermocouple connection bushing on gas valve 2 Remove end of thermocouple lead from thermocouple connection bushing and clean with fine sandpaper or emery cloth 3 Pilot flame may be too high or too low Adjust pilot flame adjustment screw so that pilot flame extends about 34 inch 19 mm above the top of the pilot burner 4 Check all connections for cleanliness and security 7 1 7 2 Pilot Burner Malfunction cont C Pilot flame of proper size but is unstable Flame wavers and does not envelop the thermocouple completely at all times 1 Check for drafts that might be caused by air conditioning equipment or make up air apparatus Turn air moving equipment off and recheck the pilot A CAUTION Do not attempt to turn the adjustment past the stops or the controller will be damaged 7 3 Main Burner Malfunctions Main burner will not come gas not detected at main burner 1 Check that the gas valve is open 2 Check that the pilot is ignited and is operating properly 3 Check the high limit switch for continuity 4 The combination gas valve may be defective replace if necessary Main burner flames are small and appear lazy shortening does not come up to temperature quickly 1 Check gas pressure at the pressure tap of the gas valve Use dial type or standard water type U gauge manometer With burner in operation the
36. hreads 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 Yo PSI 3 45 kPa 35 mbar a step down regulator will be required A 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 1 2 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 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 Natura
37. il display is free 5 3 5 1 2 Checking Temperature A Check the cooking oil shortening temperature at any time by pressing the 4 switch once Check the setpoint by pressing the switch twice During the idle periods when the fryer is on but not in use should appear on both displays on a single frypot computer will appear on the display of the side that is turned on in a split vat computer If not check actual temperature and setpoint If you suspect a defective probe check the cooking oil shortening temperature with a thermometer Verify that the computer readout is reasonably close to your measured reading NOTE The electronic circuitry can be affected adversely by current fluctuations and electrical storms If for no apparent reason the computer does not function or program properly reset the computer by unplugging the power cord and plugging it back in 5 2 Programming The Dean Compu Fry Computer 1 2 Activate the computer by pressing either O switch To enter the program mode first press the switch will appear in the left display If you have pressed this switch in error and do not wish to program press the switch again Note The computer will flash B U 5 if cooking is in progress
38. ional Components Controllers and Related Components CE and Domestic Components are applicable to all Decathlon Fryers covered in this manual unless otherwise noted 7 WH SF RES 9 10 11 555 Ney S E ie PEN K 13 14 15 16 Ge wees 17 18 19 NS 4 20 NC Y isi d 21 8 7 8 5 Decathlon Component Options CE and Domestic cont ITEM PART COMPONENT 1 2557 Thermostat Sunne 2 1205 Knob Thermostat Domestic 1205 1 Knob Thermostat CE ONLY 3 2167 Spark Module Domestic and CE 4 44907 1 Pilot Assembly For Natural Gas a 44907 2 Pilot Assembly For LP Gas 14199 1 Pilot Assembly Nat Gas G 20 25 ONLY 14199 2CE Pilot Assembly LP Gas G 31 37 50 CE ONLY 5 50 0004 Control Panel D 20 50 0004 Control Panel 0 50 60 0004 2 Control Panel D 60 20 0044 1 Control Panel D 80 6 12148 Bezel Assembly Control Panel 7 2444 Computer Dean 8 14702 G0 Face Plate Potentiometer PC Board Assembly 120 VAC 18 0133 Face Plate Thermatron 18142 Potentiometer Thermatron 1543 Knob Control Thermatron 9 2560 Electrode 10 2654 Thermocouple 11 2650 ECO Connector Assembly 12 14707 Probe Assembly Temperature Thermatron 00 12147 Probe Assem
39. iquid cleanser designed for stainless steel at the end of each day A Do not use steel wool abrasive cloths cleansers or powders B Do not use a metal knife spatula or any other metal tool to scrape stainless steel Scratches are almost impossible to remove If itis necessary to scrape the stainless steel to remove any encrusted materials soak the area first to soften the deposit then use a wood or nylon scraper only 6 2 DECATHLON SERIES GAS FRYERS CHAPTER 7 TROUBLESHOOTING 7 1 General A CAUTION This appliance may have more than one power supply connection point Disconnect all power cords before servicing The problems and possible solutions covered are those most commonly encountered To troubleshoot perform the test set up at the beginning of each condition Follow each step in sequence WARNING Inspection testing and repair of gas or electrical equipment should be performed by qualified personnel Use EXTREME CARE when testing Live Electrical Circuits 7 2 Pilot Burner Malfunction A Pilot will not ignite no evidence of gas at pilot burner 1 Check that gas valve is open and gas is present at the gas valve 2 Check pilot burner orifice for dirt or lint 3 Remove pilot burner gas supply line and check for contamination blow out if necessary then reinstall B Pilot burner ignites but will not remain lit when gas valve manual knob is released 1 C
40. l 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 A 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 A 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 imme
41. ll 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 DECATHLON SERIES GAS FRYERS CHAPTER 3 INSTALLATION 3 1 Installing the Fryer 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 Relocating the fryer Remove all weight from each leg before moving a fryer with legs installed Do not slide the fryer on the legs If a leg becomes damaged contact your service agent for immediate repair replacement 3 2 Leveling the Fryer Fryers equipped with legs only A B All Installations If the floor is uneven or has a definite slope it is recommended to place the fryer on an even platform 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 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 Re leveling If the fryer is m
42. m the vessel 4 4 4 2 2 Filtration Boil Mode Option Equipped Fryers cont A CAUTION All drops of water MUST be removed from fry vessel before filling with cooking oil Do not turn fryer on to dry extensive damage will occur to fry vessel and burner tubes and ALL warranties will be voided NOTE For a fresh start and prolonged fry vessel life it is recommended that the boil out procedure 4 2 3 be performed each time the oil shortening is changed Computer Equipped Fryers Before switching the fryer s ON close the fry vessel drain valve s Fill the empty fry vessel with a mixture of cold water and boil out solution Follow instructions when mixing To program computer for Boil Feature press either switch Press the switch CogE will appear the left display TL 6 SCI 3 Enter 1 6 5 3 in that sequence The right display will read o i L The temperature is automatically set for 195 F 91 C The fryer will attain this temperature and remain there until either O switch is pressed which cancels the boil out mode In high altitude locations constantly monitor the fryer for over boil conditions If over boil occurs turn off fryer immediately allow to cool and re enter boil out
43. mode to continue the boil out operation 4 3 Final Preparation WARNING NEVER set a complete block of solid shortening on top of heating tubes To do so will damage the heating tubes and fry vessel and void the warranty 4 3 1 A Filling Fryer with Cooking Oil Shortening Operating Thermostat Thermatron When using a liquid shortening cooking oil fill the fryer to the bottom OIL LEVEL line scribed into the back of the fryer vessel When using a solid shortening first melt it in a suitable container or cut it into small pieces and pack it below the heat tubes between the tubes and on top of the tubes leaving no air spaces around the tubes Do not disturb or bend the sensing bulbs 4 5 C If equipped with a Melt Cycle Control turn the melt cycle switch ON to melt the shortening The burners will cycle on and off until shortening has melted D If the fryer does not have a Melt Cycle Control 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 cycle and lengthen the OFF cycle Smoke indicates potential scorching of the shortening which will shorten its useful life E Before starting operation turn the operating thermostat to the probable working temperature wait for the temperature to stabilize then check with a high quality imm
44. nce IDESDP IDL3P Netherlands 37 and GB Great Britain cT PT Portugal K 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 A 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 t
45. ntainer 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
46. ounds A good initial setting is 4 or 5 Some experimenting with the range of 1 to 9 may be required to achieve optimum quality 14 C 0 0 C will now appear in the left display A previously entered cook time will appear in the right display If that time is correct press the switch If you wish to change the time enter the desired time in minutes and seconds The new time will be displayed in the left display Press the switch to lock in the setting 5 5 5 2 Programming The Dean Compu Fry Computer cont 15 5 H now appears in the left display The previous shake time if any will appear in the right display If a product requires shaking during the cooking process set the shake time by pressing the number of minutes to cook before shaking Press the Y switch to lock in the time If no shake time is required press 0 and press the minutes shake after cooking 1 00 minute switch Example Total cook time 3 00 16 At the end of 1 00 minute a beeper will sound and the product button indicator will flash for 3 seconds 17 Hd will now appear in the left display Set the time to hold the cooked product from 13 seconds to 60 minutes Press the V switch If you do not wish to use the hold time enter 0 switch and press the
47. oved re level the fryer following the above instructions The install must be reviewed at the time of installation to ensure it meets the intent of these instructions A 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 A 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
48. position the display will show OFF 2 Filter vegetable oil if applicable and clean fryers See Chapter 6 3 Place the frypot covers frypots Operating the Fryer A Turn the computer on by pressing the switch 1 One of the following displays will appear a CYC L indicating that the burners are operating in the melt cycle mode Fryer will remain in the melt cycle mode until it reaches 180 F 82 C or is canceled manually b indicating that the pot temperature is 21 F 12 C or higher than the setpoint LO indicating that the pot temperature is 21 F 12 C or lower than the setpoint 5 2 5 1 1 Equipment Setup and Shutdown Procedures cont d indicating that the fryer temperature is in the cooking range NOTE For best results do not cook product until the display reads HELP indicates a heating problem f indicates that the pot temperature is more than 410 F 210 C 395 F 202 C for CE European Community fryers g Prob indicates that the computer has detected a problem in the temperature measuring circuits including probe NOTE decimal point between digits 1 and 2 in either display area indicates that the burners are on B Melt Cycle Cancel Feature built in computers only A CAUTION Do not cancel the melt cycle mode if using solid shortening The computer
49. pplied to the back up thermostat of each fryer The back up thermostat should be left in the OFF position when not in use Newer fryers may not have the backup control option 5 3 Operating Fryers with Thermatron Controllers cont INDIVIDUAL FRYER POWER SWITCH this switch controls power to the individual fryer whether the fryer is in the Thermatron mode or the back up mode When the power switch is in the ON position the indicator light will be lighted when calling for heat The power switch only removes power from the temperature control circuit Thermatron and Back Up Thermostat The power switch should be in the OFF position during filtering BOIL OUT SWITCH this only operates when in the Thermatron mode When the Boil Out switch is ON it will bypass the Thermatron Melt Cycle and allow the water temperature to reach approximately 196 F FILTER POWER SWITCH Optional controls power to the filter pump Individual Power Switch should be in OFF position when in use HIGH LIMIT RESET this reset button is located under each individual control panel and must be manually reset if the fryer exceeds high limit setpoint FILTER RESET SWITCH 7 Amp Circuit Breaker the breaker is in line between the filter switch and the pump Turn filter power switch OFF prior to replacing 5 AMP FUSE each two fryer circuits are protected by 5 amp fuse located under the 24 and 4 control panel 5 9 DECATHLON SERI
50. pressure should be 4 WC 10 mbar for natural gas and 11 WC 27 5 mbar for propane 2 If not remove the pressure regulator adjustment cover Use screwdriver to turn the adjusting screw for proper pressure Replace cover re check pressure and re install pressure tap plug Signs of excessive temperature shortening scorches and quickly becomes discolored 1 Check operating thermostat be out of adjustment or calibration Recalibrate if necessary 2 Check gas pressure as outlined above 3 Shortening used is of inferior quality and or shortening has been used too long Replace shortening 4 Ensure vessel is clean when refilling with new shortening 7 2 7 3 Main Burner Malfunctions cont D Fryer will not reach the temperature setting and or runs erratically 1 Incorrect location of sensor probe or defective temperature sensor 2 Loose wiring wire connection E Fryer shortening temperature cannot be controlled fryer runs at high limit temperature 1 Defective operating thermostat or temperature probe 2 Call Service Technician 7 4 Thermatron Calibration The Thermatron controller maintains a specific oil shortening temperature through a sensing probe mounted in the fry vessel If the actual temperature of the cooking oil varies from the controller dial setting loosen the knob setscrew and rotate the knob until it agrees with that of the actual oil temperature When obtaining actual oil temperature en
51. s 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 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 Never use the interior of the fryer cabinet for storage or store items on shelving over or behind the fryer Exhaust temperatures can exceed 425 C and may damage or melt items stored in or near the fryer 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 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 B 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 The correct orifices are installed at the factory if operating altitude is known at time of the customer s order
52. sel are tight A CAUTION 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 fit tight and should only be removed for cleaning 4 1 1 Pilot Lighting Procedures Standing Pilot Only Initial Pilot Light All Dean fryers are tested adjusted and calibrated to sea level conditions before leaving the factory Adjustments to assure proper operation of pilot may be necessary on installation to meet local conditions low gas pressure differences in altitude and variations in gas characteristics These adjustments correct possible problems caused by rough handling or vibration during shipment and are to be performed only by qualified service personnel These adjustments are the responsibility of the customer and or the dealer and are not covered by the Dean Industries watranty The inlet pipe at the lower rear of the fryer brings incoming gas to the pilot safety control valve then to the pilot and main burners The pilot is located high in the cabinet center at the base of the fryer vessel Light the pilot as follows 1 Turn off the manual shut off valve on the incoming service line 2 Turn the operating thermostat or the computer off 3 Depress the pilot gas cock dial on the combination control valve and turn to OF
53. sure that the thermometer is inserted within one inch of the vessel mounted probe If proper calibration cannot be achieved contact your service agent for repair Control Knob Setscrew counter set in knob Thermatron Probe 7 3 iring 7 4 W 7 4 1 Decathlon Dual vat Thermatron Only Y3ATIOULNOOS H3TIOHLNOO 3HN1VH3d4W3L 31915 1105 31915 anos 09 IVA 021 409 IVA 021 SNOHLVWH3HL 38 1n0 108 311 16 1 4 HOSN3S HOLIMS 08 lVISOWHSHL Vi 1 A anayovaa 1 ATA svo 1VISOWH3HL t TLA n mais dene dida 1 i JAVA te s re Svo i ST IMYA i 1 i Av 3H anaon NOLLINOI TINON NOILINOI Ave ASI Se I HOLINOI 41 c SAT HOLINOI IS JAWA svo HOLINOI 1VISOWH3HI 2 asna 5 9 1VISONHAHL LIWITHH HOLIMS HOLIMS H3ONO10N 0 440 SLINN 43070 NO G3SN JALLVNU3LTV 9061 F7NGOW NOLLINOI 1331 HOSN3S dial 7 4 7 4 2 Decathlon Dual vat Computer Option
54. t leave fryer unattended The boil out solution may foam and overflow if fryer is left unattended Press ON OFF switch to the OFF position to control this condition D The burners will heat the boil out solution to a simmer Simmer the solution for approximately 45 minutes Wearing protective gloves scrub the sides of the fry vessel and the tubes with the L shaped teflon brush being careful not to disturb the temperature sensing probes and the high limit thermostat E Do not allow the water level to decrease below the bottom OIL LEVEL line in fry vessel during boil out operation A CAUTION Water or boil out solution MUST not be allowed to drain into the filter pan or filter system Irreversible damage will result if water is allowed into the system F After boil out is complete turn the boil out and fryer switches to OFF and drain the solution from the fry vessel Place a metal pan or bucket under the drain port to collect the water from the fry vessel DO NOT DRAIN THE WATER INTO THE FILTER PAN The filter pump is not designed for water operation and will be irreparably damaged G Close the drain add fresh water without boil out solution and wash all surfaces of the fry vessel Drain again H Refill the fry vessel with fresh water and vinegar to neutralize any residual boil out solution Wash all surfaces of the fry vessel Drain completely and wipe down all surfaces of the fry vessel to completely eliminate water fro
55. will display C C L during melt cycle operation To cancel melt cycle on a full pot depress the R button To cancel the melt cycle on a split pot use button O for left side pot and the R button for right side pot L will be replaced by Lo The decimal point between digits 1 and 2 will illuminate indicating that the burners are on C Cook cycle operation is initiated by pressing the product switch 1 The basket lift on fryers so equipped will lower the product into the cooking oil shortening 2 display will indicate the programmed cook time and begin countdown 3 If shake time is programmed you will be notified to shake the product X seconds after the cook cycle begins X amount of time programmed An alarm will sound and the display will read 5 H and the product number selected If no shake time is programmed 5 will not appear during the cook cycle 4 At the end of cooking cycle an alarm will sound C GG C will be displayed and the associated product switch indicator will flash To cancel the cook alarm press the flashing product switch 5 Atthis time the hold time will be displayed if programmed greater than 0 and countdown will begin When the hold time counter reaches 0 an alarm will sound Hg and the product number selected is displayed The hold alarm is canceled by pushing the switch If display is in use hold time will count down invisibly unt
56. with the appropriate rocker switch or controller computer 3 The electric module will turn on the pilot gas supply and the electric ignition spark The spark will ignite the pilot gas The presence of the pilot flame is then proved by the electric flame sensor which in turn allows the main gas supply to be turned on The operating thermostat or computer controller controls the fryer after ignition is proved 4 2 4 1 2 Pilot Lighting Procedures Electronic Ignition Systems cont A WARNING In the event of prolonged power failure the ignition module will shut down and lock out the system Turn the unit power OFF and them back ON after power has been re established 4 If the pilot flame fails the ignition module will shut down and lock out the system To restart turn the electric power OFF wait approximately 5 minutes for the system to recycle itself then turn the power ON again Repeat Steps 1 3 4 2 Boil Out Procedure 4 2 1 Thermostat Equipped Fryers A cn Pour cleaning solution into the fry vessel and add water to the bottom OIL LEVEL line scribed in the back of the fry vessel Set the operating thermostat dial temperature controller to 104 C 21992 just above that of boiling water The main burner will ignite Reset the temperature controller to 93 C 199 4 F The burners should shut off just as the water starts to boil The burners will heat the boil out solution to a simmer
57. y 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 A 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 A 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 A 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 co
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