Decathlon Series Gas Fryers (D & HD Models) Installation & Operation Manual - DEAN D, SCFD, and CFD Models - DEAN HD and SCFHD Models - FRYMASTER FPD65 and FPHD65 Models Please read all sections of this manual and retain for future reference. NON-CE & Dean, a member of the Commercial Food Equipment Service Association, recommends using CFESA Certified Technicians.
NOTICE This appliance is intended for professional use only and is to be operated by qualified personnel only. A Frymaster and Dean Factory Authorized Service Center (FASC) or other qualified professional should perform installation, maintenance, and repairs. Installation, maintenance, or repairs by unqualified personnel may void the manufacturer’s warranty. See Chapter 1 of this manual for definitions of qualified personnel.
DANGER Adequate means must be provided to limit the movement of this appliance without depending upon the gas line connection. Single fryers equipped with legs must be stabilized by installing anchor straps. All fryers equipped with casters must be stabilized by installing restraining chains. If a flexible gas line is used, an additional restraining cable must be connected at all times when the fryer is in use. DANGER The front ledge of the fryer is not a step. Do not stand on the fryer.
High Efficiency Decathlon (HD) Series Gas Fryers Installation & Operation Manual TABLE OF CONTENTS Page # 1. INTRODUCTION 1-1 1.1 Applicability and Validity 1-1 1.2 After Purchase 1-1 1.3 Ordering Parts 1-1 1.4 Service Information 1-2 1.5 Computer Information 1-2 1.6 Safety Information 1-3 1.7 Service Personnel 1-3 2. IMPORTANT INFORMATION 2-1 2.1 Receiving and Unpacking Equipment 2-1 2.2 General 2-1 2.3 Product Description 2-2 2.4 Principles of Operation 2-2 2.
High Efficiency Decathlon (HD) Series Gas Fryers Installation & Operation Manual TABLE OF CONTENTS (CONT.) Page # 4. FRYER OPERATIONS 4-1 4.1 Initial Start-up 4-1 4.2 Boil-Out Procedure 4-3 4.3 Final Preparation 4-5 5. CONTROLLER OPERATING INSTRUCTIONS 5-1 5.1 Operating Instructions: Electronic Thermostat Controller 5-1 5.2 Electronic Thermostat Controller/Computer with Back-Up Thermostat 5-2 6. FILTRATION 6-1 6.1 General 6-1 6.2 Filter Preparation 6-1 6.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 1: INTRODUCTION 1.1 Applicability and Validity The Dean Decathlon Series gas model family (D models) has been approved by the European Union (EU) for sale and installation in the following EU countries: AT, BE, KE, KD, ES, FI, FR, GB, IE, IT, LU, NL, NO, PT and SE. The Dean High Efficiency Decathlon Series gas model family (HD models) has not been approved by the European Union (EU) for sale or installation in EU countries.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 1: INTRODUCTION 1.4 Service Information Call the Dean Service Hotline, 1-800-551-8633, for the location of your nearest factory authorized service center. To assist you more efficiently, always provide the service technician with the model number, gas type, serial number, and the nature of the problem. 1.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 1: INTRODUCTION 1.7 Service Personnel A. Qualified and/or Authorized Operating Personnel 1. Qualified/authorized operating personnel are those who have carefully read the information in this manual and have familiarized themselves with the equipment functions, or have had previous experience with the operation of equipment covered in this manual. B. Qualified Installation Personnel 1.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2.1 Receiving and Unpacking Equipment A. Check that the container is upright. Use an outward prying motion - no hammering - to remove the carton. Unpack the fryer carefully and remove all accessories from the carton. Do not discard or misplace these, as they will be needed. B. After unpacking, immediately check the equipment for visible signs of shipping damage.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2.2 General (cont.) Where conflicts exist between instructions and information in this manual and local code or national codes, or regulations, installation and operation shall comply with the codes or regulations in force in the country in which the equipment is installed.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2.5 Rating Plate This is attached to the inside front door panel. Information provided includes the model and serial number of the fryer, BTU/hr input of the burners, outlet gas pressure in inches W.C. and whether the unit has natural or propane gas orifices. DANGER Fryers MUST be connected ONLY to the gas type identified on the attached rating plate. 2.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2.6 Pre-installation (cont.) C. Installation Standards 1. U.S. installations must meet: 2. Canadian installations must meet: American National Standard Institute ANSI Z83.11 American Gas Association 8501 E.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2.7 Air Supply and Ventilation (cont.) D. Do not place the fryer’s flue outlet directly into the plenum of the hood, as it will affect the gas combustion of the fryer. E. Never use the interior of the fryer cabinet for storage or store items on shelving over or behind the fryer. Exhaust temperatures can exceed 800°F (427°C) and may damage or melt items stored in or near the fryer. F.
DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.1 Installing the Fryer NOTE: HD Series fryers have not been approved for use in the European Union (EU) and cannot be sold or installed in EU countries. Only D Series fryers have been approved for sale and installation in EU countries. A. Initial Installation: If the fryer is installed with legs, do not push the fryer to adjust its position.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.3 Installing Casters and Legs A. Install casters and/or legs near where the fryer is to be used, as neither is secure for long transit. Decathlon Series gas fryers cannot be curb-mounted and must be equipped with either legs or casters provided. B. After unpacking, use a pallet or lift jack to raise the unit before installing the casters. C. Align the caster or leg base holes with the leg support assembly and insert bolt.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.4 Gas Connections DANGER Before connecting new pipe to this appliance the pipe must be blown out thoroughly to remove all foreign material. Foreign material in the burner and gas controls will cause improper and dangerous operation. U.S. NATIONAL CODE REQUIREMENTS This equipment is to be installed in compliance with the Basic Plumbing Code of the Building Officials and Code Administrators International, Inc.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.4 Gas Connections (cont.) Gas Supply Type and Pressure Gas Supply Type Natural Gas Propane (LP) Gas Gas Supply Pressure 6-10" W.C. (Dynamic) 11-13" W.C. (Dynamic) DANGER When pressure-testing incoming gas supply lines, disconnect the fryer from the gas line if the test pressure is ½" PSI [3.45 kPa (14 inches W.C.)] or greater to avoid damage to the fryer’s gas piping and gas valve(s).
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.4 Gas Connections (cont.) DANGER When pressure-testing incoming gas supply lines, disconnect the fryer from the gas line if the test pressure is ½" PSI [3.45 kPa (14 inches W.C.)] or greater to avoid damage to the fryer’s gas piping and gas valve(s). D. Manifold Pressure: Your local service technician should check the manifold pressure with a manometer. 1. Check the rating plate for specific manifold gas pressures.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.5 Gas Connections (cont.) 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. Restraining brackets are located on the back panel of the fryer for the attachment of restraints. 3.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.5 Gas Specifications CE ONLY (Altitudes of 2000 feet or less) EQUIPMENT PRESSURE MBAR INCH W.C. 10,0 4,0 15,0 6,0 27,0 10,8 MODEL INPUT (kW) GAS TYPE ORIFICE (MM) ORIFICE PART NO.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 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). DANGER This fryer is equipped with a three-prong (grounding) plug for protection against electrical shock and must be plugged directly into a properly grounded, three-prong receptacle.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.1 Initial Start-up WARNING The on-site supervisor is responsible for ensuring that operators are made aware of the inherent hazards of operating a hot oil frying system, particularly the aspects of system operation, oil filtration, draining and cleaning procedures.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.1.1 Pilot Lighting Procedures, Standing Pilot Only Initial Pilot Lighting: 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.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.1.2 Pilot Lighting Procedures, Electronic Ignition Systems WARNING Never use a match or taper to light pilot on this ignition system. 1. Turn gas "ON". 2. Turn electric power "ON" with the appropriate rocker switch or controller/computer. 3. The ignition module will energize the pilot gas supply and the igniter. The igniter spark will ignite the pilot gas.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.2 Boil-Out Procedure (cont.) A. Pour cleaning solution into the frypot and add water to the bottom OIL LEVEL line scribed in the back of the frypot. B. Operating thermostat-equipped fryers: Set dial/temperature controller to 225°F (107ºC), just above that of boiling water. C. Filtration/Boil-Mode equipped fryers: Turn fryer power switch to "ON". Press the fryerreset switch (if applicable). Turn the boil-out switch "ON".
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.2 Boil-Out Procedure (cont.) J. Close the drain, add fresh water (without boil-out solution) and wash all surfaces of the frypot. Drain again. K. Refill the frypot with fresh water and vinegar to neutralize any residual boil-out solution. Wash all surfaces of the frypot. Drain completely and wipe down all surfaces of the frypot to completely remove all water.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.3 Final Preparation (cont.) D. Operating Thermostat: 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. Compu-Fry Computer: Press the computer on/off switch to "ON".
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 5: CONTROLLER OPERATING INSTRUCTIONS 5.1 Operating Instructions: Electronic Thermostat Controller Decathlon Series gas fryers come standard with an electronic thermostat controller, which incorporates a temperature-control circuit board, a potentiometer, and a temperature probe. The potentiometer knob is turned to the desired temperature setting, similar to a standard thermostat.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 5: CONTROLLER OPERATING INSTRUCTIONS 5.1 Operating Instructions: Electronic Thermostat Controller (cont.) FRYER POWER SWITCH – This switch turns the fryer on and off. When the power switch is in the "ON" position, the indicator light will be lit when calling for heat. BOIL-OUT SWITCH (Optional) – When the boil-out switch is "ON", it will bypass the electronic thermostat melt-cycle, and allow the water temperature to reach approximately 196°F (91°C).
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 5: CONTROLLER OPERATING INSTRUCTIONS 5.2 Electronic Thermostat Controller/Computer (cont.) MAIN POWER SWITCH – connects/disconnects primary power; double-lighted with center position "OFF". One main switch controls two electronic thermostats/Compu-Fry or remote computers. When the main power switch is in the center position, power is removed from the two fryers controlled by the electronic thermostats/Compu-Fry or remote computers.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 6: FILTRATION 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. 6.1 General Most SUFF/UFF systems use filter paper as the filter medium. Some filter systems can be special ordered with a filter-leaf assembly, which eliminates the need for filter paper.
SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6.2 Filter Preparation On initial installation and before each use, clean the filter: a. remove all loose parts from the filter, b. wash the filter pan and all accessories in hot, soapy water, c. and dry thoroughly. 6.2.1 Filter Unit Types FILTER PAPER AND HOLD DOWN RING Filter paper is held in place by a hold-down ring. Oil moves through the paper, leaving behind impurities. 1. Filter pan. 2. Filter support grid. 3. Filter paper.
SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6.2.1 Filter Unit Types (cont.) FILTER LEAF A filter leaf is a fine mesh screen which is reusable and takes the place of disposable paper. Oil moves through the leaf, leaving behind impurities. 1. Filter pan. 2. Filter leaf. 4 3. Crumb Screen. 4. Filter pan lid. 5. Caster. 3 2 1 5 A filter unit which utilizes a filter leaf to filter the oil.
SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6.2.2 Assembling the Filter FILTER PAPER AND HOLD DOWN RING 1. Place the support grid in the bottom of filter pan. Support grid properly placed in filter pan. 2. Put one filter paper sheet on top of the support grid. Be sure the paper covers the filter pan bottom and laps two inches onto the pan wall. Ensure filter paper overlaps two inches on all sides and is evenly distributed under the holddown ring. 3.
SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6.2.2 Assembling the Filter (cont.) 4. Sprinkle 8 ounces (227g) of filter powder on the filter sheet. Ensure the powder covers the filter paper evenly. Sprinkle the proper amount of filter powder evenly over the paper. 5. Place the crumb screen in the filter pan. Allow the crumb screen to rest on the top edges of the hold-down ring. Crumb screen properly placed. 6. Place filter pan cover onto the filter pan assembly.
SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6.2.2 Assembling the Filter (cont.) FILTER LEAF 1. Remove the filter pan from the fryer by pulling out on the filter pan handle. 2. Remove the filter pan lid picking it up off of the pan. handle Pull out on the handle to remove the filter pan. 3. Remove the crumb basket by lifting it up and out of the filter pan. Be careful not to damage the tubes or connectors in the pan. Remove the crumb screen by lifting it up and out. 4.
SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6.2.2 Assembling the Filter (cont.) 7. Sprinkle 8 ounces (227g) of filter powder on the filter leaf. Ensure the powder covers the mesh evenly. Applying filter powder to filter-leaf. 8. Replace the crumb tray in the pan after filter powder application. Crumb screen properly placed in filter pan. 9. Replace the pan lid. Ensure the pickup tube is properly positioned in the pan lid access hole.
SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6.2.3 Installing the Filter 10. Slide the filter inside the fryer cabinet. Ensure the male-female pickup tubes are fully engaged. Ensure the filter pan opening is directly under the center dump tube. The filter pan slides under the fryer (left), connecting with a male connector (right). Ensure that the pickup tube is securely coupled with this connector. Its location may vary based on model. 6.
SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6.3.2 Filtering Tools Assemble tools to be used for filtering. These are supplied with the filter starter kit included with the fryer/filter system: • • • • Frypot/Filter Brush - used to clean frypot and filter pan sides and bottom, heating elements, and to dislodge sediment during filtration or oil change. Clean-out Rod (design may vary) - used to dislodge heavy debris in the drain tube (when needed). Filter Powder.
SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6.4 Operating the Filter 6.4.1 Pan Preparation and Operation See Section 6.2.1, Assembling the Filter, and Section 6.2.2, Installing the Filter, for the appropriate filter preparation procedure. For optional filter hose and wand, see Section 6.4.3, Optional Filter Hose and Wand Operation. CAUTION NEVER operate the filter unit unless cooking oil is at operating temperature (~350°F/ ~177°C). 1.
SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6.4.1 Pan Preparation and Operation (cont.) 4. After ensuring the filter pan is correctly positioned under the drain tubes, move the red handle to the open position (right) to drain the frypot into the filter pan. Drain ONLY one frypot at a time. The filter pan is designed to hold the contents of one frypot only. Move the red drain valve handle into the open position. 5.
SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6.4.2 Filter Operation 6. Oil will begin to pump from the filter pan into the frypot. If the frypot tubes, sides and bottom have sediment deposits, clean the frypot with the cleaning brush included with the fryer. Clean beneath and under the burner tubes, using care not to disturb the probes (arrow). Clean all sediment and suspended particles from the burner tubes and frypot as the oil begins to circulate.
SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6.4.2 Filter Operation (cont.) 9. After all oil is pumped back into the frypot, bubbles will form, indicating air in the oil return lines. Allow the oil to bubble for 1015 seconds to ensure all oil is evacuated from the return lines. Push the yellow handle to close the oil return valve and deactivate the filter pump (see Step 5 above for additional reference).
DECATHLON SERIES GAS FRYERS CHAPTER 5: UNDER FRYER FILTER (SUFF/UFF) FILTRATION 6.4.2 Filter Operation (cont.) 12. Do not allow crumbs to accumulate in the crumb tray. The crumb tray MUST be emptied into a fireproof container at the end of frying operations EACH DAY (see DANGER statement below). Empty the filter pan crumb tray into a fire-proof container at the end of frying operations each day. DO NOT ALLOW CRUMBS TO ACCUMULATE IN TRAY.
SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6.4.3 Optional Filter Hose and Wand Operation Some frying systems come equipped with an optional filter hose, wand, and toggle switch to facilitate the removal of debris from the frypot. The hose attaches to a no quick-disconnect on the bottom front of the fryer and is controlled using a toggle switch on the fryer control panel. 1. Ensure the oil is at operating temperature (~350°F/~177°C). Turn the fryer off and open the fryer drain valve.
SUFF/UFF FILTRATION SYSTEMS CHAPTER 6: INSTALLATION AND OPERATION 6.4.3 Hose and Wand Operation (cont.) 4. The oil will start to flow immediately into the frypot. Keep the wand inside the frypot at all times while the filter pump is activated. Yellow Red The red handle is attached to the drain valve. The yellow handle is attached to the oil return valve. 5. Rinse debris from the frypot into the filter pan with the wand.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 7: PREVENTATIVE MAINTENANCE DANGER Never attempt to clean the fryer during the cooking process or when the frypot is filled with hot oil/shortening. If water comes in contact with oil/shortening heated to cooking temperature, it will cause spattering of the oil/shortening, which can result in severe burns to nearby personnel. Any equipment works better and lasts longer when maintained properly and kept clean. Cooking equipment is no exception.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 7: PREVENTATIVE MAINTENANCE 7.3 Periodic/ Annual The fryer should be inspected and adjusted periodically by qualified service personnel as part of a regular kitchen maintenance program. Dean recommends that the fryer be inspected at least annually by a Factory Authorized Service Technician as follows: • Inspect fryer cabinet inside and out, front and rear, for excessive oil build-up and/or oil migration.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 8: TROUBLESHOOTING DANGER Hot shortening will cause severe burns. Never attempt to move this appliance when filled with hot shortening or to transfer hot shortening from one container to another. DANGER This equipment should be unplugged when servicing, except when electrical circuit tests are required. Use extreme care when performing such tests. This appliance may have more than one electrical power supply connection point.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 8: TROUBLESHOOTING 8.1 Pilot Burner Malfunction (cont.) C. Pilot flame of proper size, but is unstable. thermocouple completely at all times. Flame wavers and does not envelope the 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. 8.2 Main Burner Malfunctions A. Main burner will not come "ON"; gas not detected at main burner. 1.
HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 8: TROUBLESHOOTING 8.2 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; Call Authorized Service Agent. 8.
Dean, 8700 Line Avenue, PO Box 51000, Shreveport, Louisiana 71135-1000 Shipping Address: 8700 Line Avenue, Shreveport, Louisiana 71106 TEL 1-318-865-1711 PRINTED IN THE UNITED STATES FAX (Parts) 1-318-688-2200 SERVICE HOTLINE 1-800-551-8633 FAX (Tech Support) 1-318-219-7135 819-5698 MAY 2007
