Super Marathon Series Gas Fryers Installation & Operation Manual Series SM20, SM40, SM50, SM60 & SM80 NON-CE & Dean, a member of the Commercial Food Equipment Service Association, recommends using CFESA Certified Technicians. PRINTED IN THE USA www.frymaster.com 24-Hour Service Hotline 1-800-551-8633 E-mail: service@frymaster.
Please read all sections of this manual and retain for future reference. NOTICE This appliance is intended for professional use only and is to be operated by qualified personnel only. A Frymaster Dean Factory Authorized Servicer (FAS) 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 The front ledge of the fryer is not a step. Do not stand on the fryer. Serious injury can result from slips or contact with the hot oil. DANGER Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other cooking appliance. DANGER Instructions explaining procedures to be followed MUST be posted in a prominent location in the event the operator detects a gas leak. This information can be obtained from the local gas company or gas supplier.
Super Marathon Series Gas Fryers Installation & Operation Manual TABLE OF CONTENTS Page # 1. INTRODUCTION 1-1 1.1 Applicability and Validity 1-1 1.2 Ordering Parts 1-1 1.3 Service Information 1-1 1.4 Safety Information 1-2 1.5 Definitions 1-2 2. IMPORTANT INFORMATION 2-1 2.1 Receiving and Unpacking Equipment 2-1 2.2 General 2-1 2.3 Principles of Operation 2-2 2.4 Rating Plate 2-2 2.5 Pre-Installation 2-3 2.6 Equipment Installed at High Altitudes 2-4 2.
Super Marathon 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. PREVENTATIVE MAINTENANCE 5-1 5.1 General 5-1 6. TROUBLESHOOTING 6-1 6.1 General 6-1 6.2 Pilot Burner Malfunction 6-1 6.3 Main Burner Malfunctions 6-2 6.4 Wiring Diagrams 6-3 6.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 1: INTRODUCTION 1.1 Applicability and Validity Dean Super Marathon Series gas model family has been approved by the European Union (EU) for sale and installation in all EU countries. This manual is applicable to and valid for all Dean Super Marathon Series gas units sold in English-speaking countries, including those in the European Union.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 1: INTRODUCTION 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 CAUTION boxes contain information about actions or conditions that may cause or result in a malfunction of your system.
SUPER MARATHON 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.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2.2 General (cont.) Dean Super Marathon Series gas fryers are energy efficient gas-fired units. All units are shipped completely assembled, with accessories packed inside the frypot. All units are adjusted, tested, and inspected at the factory prior to crating for shipment.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2.5 Pre-Installation DANGER No structural material on the fryer should be altered or removed to accommodate placement of the fryer under a hood. Questions? Call the Frymaster Dean Service Hotline at 1-800-551-8633. DANGER Do not connect this appliance to the gas supply before reviewing all information in this chapter. A. General: Only licensed personnel should install any gas-fired equipment. 1.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2.5 Pre-Installation (cont.) C. Installation Standards 1. 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. NON-CE INSTALLATION STANDARDS: Fryer installation must conform with local codes, or in the absence of local codes, to the appropriate national standards as listed below: a. U.S. installations must meet: b.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2.7 Air Supply and Ventilation DANGER This appliance must be installed with sufficient ventilation to prevent the occurrence of unacceptable concentrations of substances harmful to the health of personnel in the room in which it is installed. Keep the area around the fryer clear to prevent obstruction of combustion and ventilation airflow. 1. Do not connect this fryer to an exhaust duct. 2.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 3: INSTALLATION INSTRUCTIONS 3.1 Installing the Fryer A. Initial Installation: If installed with legs, do not push against the fryer’s side to adjust its position. Use a pallet or lift jack to lift the fryer slightly and place it where it is to be installed. B. Relocating the Fryer: If relocating a fryer installed with legs, remove all weight from each leg before moving.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 3: INSTALLATION INSTRUCTIONS 3.2 Leg and Caster Installation (cont.) 3. Rigid casters must be installed on the fryer rear-channel assembly only. 4. Proceed to Step 3.3, Leveling the Fryer, after legs and rear rigid casters are installed to ensure the fryer is level before using. B. Leg and Rigid Caster Installation 1. Remove unit from pallet. 2. Carefully raise unit with forklift, pallet jack, or other steady means. 3.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 3: INSTALLATION INSTRUCTIONS 3.3 Leveling the Fryer (cont.) Rigid Casters (Only) 1. Install the rigid casters on the fryer rear channel only. Legs must be installed on the front channel. 2. There are no level adjustments for the rigid casters. B. If the floor is uneven or has a decided slope, place the fryer on a smooth, level platform. C. If the fryer is moved, re-level the fryer following the instructions given in Steps 3.3, A-C. D.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 3: INSTALLATION INSTRUCTIONS 3.3 Leveling the Fryer (cont.) NOTE: The installation must be inspected after it is complete to ensure it meets the intent of these instructions. The on-site supervisor and/or operator(s) should be informed that the appliance is installed with restraints. If restraints are removed to move fryer (cleaning beneath and behind, relocation, etc.), ensure that they are re-installed when fryer is returned to its permanently installed position.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 3: INSTALLATION INSTRUCTIONS 3.4 Gas Connections (cont.) NATIONAL CODE REQUIREMENTS: NON-CE This equipment is to be installed in compliance with the Basic Plumbing Code of the Building Officials and Code Administrators International, Inc. (BOCA) and the Food Service Sanitation Manual of the U.S. Food and Drug Administration. This equipment is manufactured to use the type of gas specified on the rating plate attached to the door.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 3: INSTALLATION INSTRUCTIONS 3.4 Gas Connections (cont.) Supply Line Specifications The incoming gas supply line should be a minimum of 1½" (40 mm) in diameter. The gas supply lines must be sized as indicated in the chart below, based on the total number of fryers connected to the main gas supply.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 3: INSTALLATION INSTRUCTIONS 3.4 Gas Connections (cont.) Regulating Gas Pressure The fryer and shut-off valve must be disconnected from the gas supply during any pressure testing of the system. External gas regulators are not normally required on this fryer. A safety control valve protects the fryer against pressure fluctuations. If the incoming pressure is in excess of ½" PSI (3.45 kPa/35 mbar), a step-down regulator will be required.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 3: INSTALLATION INSTRUCTIONS 3.4 Gas Connections (cont.) 1. CE ONLY: The following color codes indicate the type of gas to be used for each fryer and associated components. Gas Type Natural Propane CE Color Code Blue Red E. Flexible Couplings, Connectors and Casters 1.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 3: INSTALLATION INSTRUCTIONS 3.5 Adjustments/Adaptation To Different Gases A. Proper operation of appliances requires operator to inspect the following adjustments in Section 3.6 in terms of gas inputs and pressures. B. Dean Super Marathon Series gas fryers are manufactured to use the type of gas and pressure specified on the rating plate. When changing gas, adaptation must be performed by qualified personnel.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 3: INSTALLATION INSTRUCTIONS 3.6 Gas Inputs CE UNITS ONLY: A. Nominal Heat Inputs (Qn), Gas Type, Orifice Size, Part Number and Quantity/Color are listed in the table below: MODEL NOMINAL HEAT INPUTQn (kW) SM 80 GM 37.5 SM 60 GM 37.5 SM 50 GM 30 SM 35 GM SM 40 GM 26 SM 20 GM 15 GAS TYPE ORIFICE SIZE (MM) ORIFICE PART NO. ORIFICE QTY/ COLOR G20 G25 G31 G20 G25 G31 G20 G25 G31 G20 G25 G31 G20 G25 G31 2.40 2.40 1.51 2.40 2.40 1.51 2.40 2.40 1.51 2.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 3: INSTALLATION INSTRUCTIONS 3.6 Gas Inputs (cont.) NON-CE ONLY: A. Nominal Heat Inputs (Qn), Gas Type, Orifice Size (applicable for fryer operation at altitudes of 2000 feet or less), Part Number and Quantity are listed in the table below: MODEL NOMINAL HEAT INPUT- Qn (BTU) SM 80 GM 165 SM 60 GM 150 SM 50 GM 120 SM 35 GM SM 40 GM 105 SM 20 GM 50 GAS TYPE ORIFICE SIZE (MM) ORIFICE PART NO. ORIFICE QUANTITY NAT LP NAT LP NAT LP NAT LP NAT LP 2.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 3: INSTALLATION INSTRUCTIONS 3.7 Gas Conversion Procedures DANGER This appliance was configured at the factory for a specific type of gas. Converting from one gas type to another requires the installation of specific gas-conversion components. Switching to a different type of gas without installing the proper conversion components may result in fire or explosion.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 3: INSTALLATION INSTRUCTIONS 3.7 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 in Section 3.8, Gas Conversion Components. Conversions can only be executed by qualified, factory-authorized personnel.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 3: INSTALLATION INSTRUCTIONS 3.7 Gas Conversion Procedures (cont.) NON-CE UNITS ONLY: See gas valve illustration below and gas valve, burner and orifice location on page 3-15 when performing the following conversions. When converting from natural gas to propane (or vice-versa), the following procedures apply: ♦ ♦ ♦ ♦ Burner orifices and pilot orifice MUST be replaced (see page 3-11 for required component part numbers).
SUPER MARATHON SERIES GAS FRYERS CHAPTER 3: INSTALLATION INSTRUCTIONS 3.8 Gas Conversion Components Use the following components to convert from natural gas to propane and vice-versa. See Section 3.6 for orifice quantities required for conversion.
SUPER MARATHON 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. Cleaning: New units are wiped clean with solvents at the factory to remove any visible signs of dirt, oil, grease, etc.
SUPER MARATHON 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.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.1.1 Pilot Lighting Procedures, Standing Pilot Only (cont.) 6. For CE units: Apply a lighted match or taper to the pilot burner head. Press the white pilot light button on the gas valve and hold approximately 45 seconds to 1 minute, until the pilot stays lit. For Non-CE units: Push and hold the knob in and apply a lighted match or taper to the pilot burner head.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS E. Do not allow the water level to decrease below the top OIL LEVEL line in frypot during boilout operation. WARNING Water or boil-out solution MUST not be allowed to drain into the filter pan or filter system (where applicable). Irreversible damage will result if water is allowed into the system. F. After boil out is complete, turn the thermostat dial to "OFF" and drain the solution from the frypot.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 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 frypot, and void the warranty. 4.3.1 Filling the Fryer with Oil or Shortening A. When using liquid shortening or cooking oil, fill the fryer to the bottom OIL LEVEL line scribed into the back of the frypot. B.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 5: PREVENTATIVE MAINTENANCE 5.1 General DANGER Never attempt to clean the fryer during the cooking process or when the frypot is filled with hot oil. If water comes in contact with oil heated to cooking temperature, it will cause spattering of the oil, 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.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 5: PREVENTATIVE MAINTENANCE 5.1.3 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 Servicer as follows: • Inspect fryer cabinet inside and out, front and rear, for excessive oil build-up and/or oil migration. Verify that burners and associated components (i.e.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 6: TROUBLESHOOTING 6.1 General DANGER Hot cooking oil will cause severe burns. Never attempt to move this appliance when filled with hot cooking oil or to transfer hot cooking oil from one container to another. 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. 6.2 Pilot Burner Malfunction A. Pilot will not ignite.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 6: TROUBLESHOOTING 6.3 Main Burner Malfunctions A. Main burner will not come "ON"; gas not detected at main burner. 1. Check that the gas valve is open. 2. Check that the pilot is lit and is operating properly. 3. Check the high-limit switch for continuity. 4. The combination gas valve may be defective; replace if necessary. B. Main burner flames are small and appear lazy; shortening does not come up to temperature quickly. 1.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 6: TROUBLESHOOTING 6.4 Wiring Diagrams CE UNITS ONLY: WARNING DO NOT CONNECT ANY EXTERNAL ELECTRICAL POWER TO THIS UNIT TH PP TH PP THERMOPILE HONEYWELL 807-3565 OPERATING THERMOSTAT COAXIAL LEAD TO THERMOCOUPLE 812-1284 HIGH-LIMIT HONEYWELL CE NON-CE UNITS ONLY: CONTROL CIRCUIT PILOT GENERATOR Combination Gas Valve Vent Robertshaw PILOT ADJ. 1/2 P.S.I. PILOT KNOB PILOT C 3C HONEYWELL 1/2 P.S.I.
SUPER MARATHON SERIES GAS FRYERS CHAPTER 6: TROUBLESHOOTING 6.
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Dean, 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 819-6001A OCT 2011
