Dean Equipment •Fryer Serial Numbers Slide Show •Model Number Identification •Model Prefixes •Millivolt Fryers Slide Show •Cool Zone Fryers Slide Show •Triathlon Fryers Slide Show •Flatbottom Fryers Slide Show •Electric Fryers Slide Show •Filtration Slide Show 7-1 Return to Cover
Dean Fryer Serial Numbers In the following sections explaining serial number/model number style, shading, underlining, italics and spaces between letters/numbers are used to clearly explain what each number or letter of the serial number/model number denotes. This is for illustration purposes only, and is not found in serial numbers on Dean fryer units. Original Style: Model numbers precede a series of four or five numbers in original Dean serial numbers.
Single-Letter Style: From early-1994 through mid-1997, Dean Industries used another type of serial number. Serial numbers in this period include a letter after the eighth or ninth number. As illustrated below, the first set of five or six numbers (shaded dark-gray) are the sales order number. The next three numbers (underlined) denote the manufacture order for each individual unit (e.g. 001, 002, etc.).
Model Number Identification (Except Flatbottoms) Oil capacity (pounds): G = Gas E = Electric 20, 35, 50, 60, 80 SM50G M S SR = Super Runner SM = Super Marathon D = Decathlon T = Thermatron® Controlled M = Millivolt I = Electronic Ignition (24V) HP = High Performance DI = Drop In TC = Counter Top PC = Pasta Cooker BG = Bagel Boiler RG = Rethermalizer S= Stainless Steel No "S"= Mild Steel (* See note below) * Valid only on units with current serial numbers (i.e. ending in "F95").
Model Number Identification (Flatbottoms) 2424G TI Fry-vessel dimensions, ( i.e. 24" x 24").
Millivolt Fryers Super Runner, Super Marathon & Triathlon •General Information •Components •Troubleshooting Super Runner 42 Gas Fryer 7-6
GENERAL INFORMATION The most basic of the Dean fryers are millivolt-operated and thermostat-controlled models. The Super Runner (SR) and Super Marathon (SM) models are essentially alike in operation, with the primary difference being oil capacity and physical size. The table below covers the current production units. MODEL SM20G SM35G SM50G SM60G SM80G OIL CAPACITY 20-23 lb. 35-43 lb. 35-50 lb. 60-75 lb. 80-100 lb. BTU.
Honeywell Millivolt Gas-valve Robertshaw Millivolt Gas-valve Pilot Assembly The pilot assembly consists of a pilot orifice, pilot hood, thermopile and mounting bracket. Pilot Hood The pilot serves two functions: 1. Lights the main burners Thermopile 2. Heats thermopile.
Thermostats The Robertshaw or Sunne operating-thermostats used in Dean millivolt fryers are accurate to within approximately 15°F. The manually operated thermostat operates in a range of 200400°F and is used in all Dean millivolt fryers. The high-limit thermostat acts as a safety switch to protect from extremely high oil temperatures. If the oil temperature exceeds the manufacturer’s pre-set temperature of 425450°F, the high-limit will open and de-energize the gas valve.
3. Main burner will not cycle ON as oil cools below setpoint. Probable causes: bad thermostat or poor connections/terminal crimps on wires between gas valve and/or other components. Replace crimped-on wire terminals with soldered-on terminals to ensure optimum connections. Corrosion or loose connections in a millivolt system will cause a loss of voltage, which directly affects the thermostat and main gas valve coil operation. 4. Some of the burners don’t ignite.
Combination Gas Valve White Thermopile Combination Gas Valve Red Pilot Knob Operating Thermostat TH TH TP Black Black Red Red Safety Valve High-Limit Vent ROBERTSHAW Red Black Red TP Red Red Operating Thermostat Black Yellow (Braided) Orange (Braided) Red Thermopile Red Hi-Limit Black Red Black Black Robertshaw Millivolt Gas Valve Wiring Honeywell Millivolt Gas Valve Wiring Although different in wiring and appearance, both types of gas valves operate similarly in their function.
Cool Zone Fryers Decathlon (D20, D35, D50, D60 D80) & 1414/1818/2020G •General Information •Components •Troubleshooting SCFUD60 with optional Compu-Fry Computer 7-12
GENERAL INFORMATION Dean Decathlon gas fryers are manufactured in a variety of different sizes and capacities. There are also significant differences in ignition and control systems. The Decathlon Cool Zone fryers are tube-type fryers, and may incorporate many combinations of multiple-fryer options (possibly different models in the same battery), automatic basket lifts, and built-in oil filtration systems.
Gas Pressure Dean Decathlon fryers require incoming gas pressure in the range of 6-14" WC for natural gas, and 10-14" WC for LP. For natural gas, the valve supplies 4" WC to the burners. For LP (including butane and butane mixtures) the valve is set at 10" WC to the burners. The burner flame should be a rich, blue color, turning yellow/orange as it goes through the diffusers in each burner tube.
Temperature Controls The Robertshaw or Sunne operatingthermostat and high-limit thermostat used in these fryers are the same components used in the Super Marathon millivolt fryers. In the Decathlon series however, the highlimit thermostat is normally wired in series with the gas valve main coil, instead of the pilot coil. When the high-limit switch opens, it cuts power to the gas valve, and extinguishes the main burners.
Dean has used two different styles of Thermatron® control boards, an old style and a newer style. Old-style Thermatron® interface board Old-style Thermatron® control panel New-style Thermatron® interface board New-style Thermatron® control panel The old-style Thermatron® system can be easily identified by a push-button test switch on the control panel (probe test button). The probe wires, one black and one white wire, are also an indicator of old-style systems.
The new "G0" Thermatron® system can be identified by the absence of a test button on the controller. Also, both wires connected to the probe are either dark brown or black. None of the parts for the two systems are interchangeable. The temperature/resistance characteristics are very different for each probe and the corresponding circuit board. Some Cool Zone fryers, especially for some major restaurant chains like Chili’s, may use a computer control system.
7-18 TEMP SENSOR 1 2 1 2 1 2 3 4 1 2 3 4 POT 1 2 3 4 1 2 3 4 GAS VALVE 5 6 5 6 PV MV MV/PV GND IGN TR SEN TH OPTIONAL BOIL OUT SWITCH C 1 2 3 4 5 6 7 8 9 RELAY R1 120 VAC 4 2 31 POWER SWITCH 14 3 7 8 9 10 11 12 TEMP SENSOR 120 VAC "GO" SOLID STATE TEMPERATURE CONTROLLER 13 2 1 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 IGNITION MODULE 115 VAC POWER SUPPLY 1 2 3 4 5 6 7 8 9 SENSOR IF INSTALLED, BOIL-OUT CIRCUIT WILL BE DUPLICATED FOR BOTH THERMATRONS BACK-UP OPERATING THERMOSTAT
TROUBLESHOOTING Pilot Malfunctions 1. Pilot fails to light. a. Gas valve on? b. Check pilot burner adjustment. Adjust pilot flame to extend about 1/2" above the top of the pilot burner. c. Check pilot gas line and pilot burner orifice for blockage. 2. Pilot will not stay lit after gas valve knob is released. a. b. c. d. Check that thermopile wires are tightly attached at gas valve. Pilot flame adjustment too low. Pilot flame not in good contact with thermopile due to drafts or make-up airflow.
3. Signs of excessive temperature - oil scorched/discolored. a. b. c. d. Check thermostat calibration. Gas pressure above specifications. Shortening is of inferior quality or used too long. Short circuit. Check wiring and harnesses. 4. Fryer fails to reach setpoint or runs erratic. a. Incorrect location of sensor probe or defective probe. b. Operating-thermostat or Thermatron® controller defective. 5.
Triathlon Fryers TC25 TC35 •General Information •Components •Troubleshooting Triathlon TC-25 Millivolt Fryer 7-21
General Information The Dean line of countertop fryers consists of two fryers, the TC25 and TC35. The models are very similar in appearance, but quite different in operation. They have two significant differences. The TC35 has five burner tubes, and may utilize 120VAC for power. The TC25 has only four burners and is strictly a millivolt fryer – it does not utilize 120VAC. MODEL TC25 TC35 OIL CAPACITY 25 lb. 35 lb. BTU. FRYING AREA 12.
Pilot Assembly The pilot assembly for the Triathlon systems is the same as that used in Dean millivolt fryers and accomplishes the same function. Thermostats The operating-thermostat and high-limit used in the Triathlon fryers are the same as those used in Dean Super Marathon fryers. Some of the TC35 fryers are operated by 120VAC, and use the Thermatron® temperature controller instead of the basic thermostat.
TROUBLESHOOTING 1. Pilot fails to light. a. b. c. d. Check gas line connection. Check safety shut-off valve. Excess air in gas line. Bleed line. Depress pilot knob for at least one minute when lighting. 2. Pilot fails to remain lit. a. b. c. d. e. Check thermopile leads to ensure leads are connected to gas valve. Re-light pilot by depressing the pilot knob for longer period of time. Adjust pilot flame height. Debris or excess air in gas line. Verify incoming gas pressure. Minimum readings are 3.5" WC (8.
Flatbottom Fryers 1824G 2424G •General Information •Components •Troubleshooting Dean 2424 Flat Bottom 7-25
GENERAL INFORMATION MODEL 1824G (T) OIL CAPACITY 45-70 lb. BTU 120,000 FRYING AREA 18" x 24" 2424G (T) 65-90 lb. 120,000 24" x 24" CONTROLS Thermostat (or Thermatron®) Thermostat (or Thermatron®) Dean Flatbottom fryers are unique in the Dean line. They are the only units that incorporate draft-inducers, or blowers to move combustion air through the burners. The blower is mounted in the exhaust flue area and operates by pulling air through the burners.
The Honeywell direct-spark ignition module is used in Dean flatbottom 1824 and 2424 gas fryers with direct-spark ignition. This module operates differently from the dual-stage modules previously discussed, and cannot be used to replace faulty dual-stage modules. Although similar to the Frymaster ignition module, the Dean Honeywell direct-spark module lacks an "Alarm" terminal. The Dean Honeywell module should have stickers on the top or bottom identifying it as an 11second module.
Burners The flatbottom fryers each have three burner tubes. Each burner has its own orifice, but all three burners go into a single burner/heat diffuser area under the fry vessel. The flame is drawn through the diffuser/baffle area where the heat is transferred to the bottom of the vessel, thus heating the oil.
Gas Pressure Dean Flatbottom fryers require incoming gas pressure in the range of 6-14" WC for natural gas, and 10-14" WC for LP. For natural gas, the valve supplies 4" WC to the burners. For LP (including butane and butane mixtures) the valve is set at 10" WC to the burners.
TROUBLESHOOTING Pilot Malfunctions 1. Pilot will not come on at all. a. Gas valve on? b. Check pilot gas line and pilot burner orifice for blockage. 2. Pilot will not stay lit after gas valve knob is released. a. b. c. d. Check that thermopile wires are tightly attached at gas valve. Pilot flame adjustment too low. Pilot flame not in good contact with thermopile due to drafts or make-up airflow. Thermopile defective. 3. Pilot flame goes out when burners come on. a.
Electric Fryers Super Runner 38 Electric, 1414/1818/2020E, 18UE/18E/14E, EH1721 •General Information •Components •Troubleshooting Super Runner SR38E 7-31
GENERAL INFORMATION The Dean Electric fryers are divided into two main categories. The SR (Super Runner) and Cool Zone models comprise the first category. The SR38E is an economy fryer with thermostat controls. The Cool Zone models are all essentially alike in design, with the primary differences being size, power usage, and oil capacity. Although 208VAC is the standard voltage, the Cool Zone fryers are also available in 240 VAC, 480 VAC, and other voltages used internationally.
since they are normally under protective guards on each side of the vessel. The side elements are identical, and have the same part number for both the left and right side. The elements in both types are normally wired for three-phase power, but may be wired single-phase if permitted by local electrical code and the wire size is adequate. Unlike the Frymaster electric elements, most Dean elements do not tilt, or lift out of the frypot. They are mounted through the front wall of the vessel.
Internal Operations and Systems Two contactors, one latching and one heating, control the power to the elements. The latching contactor engages when the main power switch is turned on. Power is also supplied to the thermostat or Thermatron® circuit board. The heating (or cycling) contactor energizes as the thermostat or Thermatron® calls for heat. If the high-limit thermostat opens, power is cut to the coil of the latching relay and to the thermostat or Thermatron® control system.
120VAC POWER SUPPLY 4 2 FUSE 3 1 HEATING ELEMENTS POWER POWER SWITCH SWITCH 1 HIGH- LIMIT THERMOSTAT 2 3 4 120VAC K2 K1 2 FUSE 5 AMP 3 1 COIL 3 5 2 4 6 4 RESET 4 CONTACTORS 1 24VAC SWITCH 1 2 6 3 DRAIN VALVE SWITCH OPTIONAL THERMOSTAT 1 2 3 4 5 6 7 8 9 1 2 3 5 6 7 8 9 FUSE BLOCKS POT OPTIONAL DRAIN VALVE SAFETY CIRCUIT 1 1 2 3 4 1 2 4 2 3 4 5 6 7 8 9 4 6 4 2 5 3 1 1 3 L3 L2 L1 2 LINE VOLTAGE 3 7 FILTER SWITCH 8 9 10 11 12 CIRCUIT BREAKE
TROUBLESHOOTING 1. The most frequent problem is that the fryer will not heat at all. First, ask these questions: a. Is the fryer plugged in (three-phase plug)? b. Is the three-phase circuit breaker tripped? c. Is the drain valve microswitch activated (if so equipped)? If so, reset safety switch. 2. If those are OK, next check the temperature control circuit. a. With unit calling for heat, is there power going into the thermostat/Thermatron board? b.
Filtration Super Cascade; Under Fryer Filter; Cascade; Single Under Fryer Filter; Micro-Flo/Built-In and Micro-Flo Portable Filters •General Information •Systems/Components •Troubleshooting Dean Under Fryer Filter (UFF) Filtration System 7-37
General Information Dean manufactures four major types of oil/shortening filtration systems. Each system is unique in design and appearance, but all accomplish the same job. The filtration systems, with a couple of notable exceptions, have the same basic components for the filtration process. Each incorporates a main filter pan, with a filter screen or grid on the bottom of the filter pan. On top of the filter screen, filter paper and filter powder are placed.
Super Cascade Filter (SCF) Super Cascade filter systems are installed into batteries of two or more fryers. It fits under two fryers and does not take up any additional floor space. If there are more than two fryers in the battery, the filter system is normally under the outermost fryers on either end. On old-style systems, the pump and motor are built into the fryer, and the filter unit couples onto the pump with a quick-connect coupling.
Cascade Filter (CF) The Cascade filter system is designed to fit under single fryers, either in a battery or as a stand-alone fryer-filter unit. Cascade filter units do not require additional floor space. If the filter is part of a battery, it always is installed under the fryer on the right end. The filter pump and motor are built into the front of the filter assembly. The unit is selfcontained, just requiring a power receptacle. A "CF-ready" fryer has a receptacle for the filtration built into the fryer.
Single Under Fryer Filter (SUFF) Single Under Fryer Filters (SUFF) are designed differently from earlier Cascade Filters (built before late-1999). The new design couples to the oil return system similarly to the new Under Fryer Filter system. Also, the filter pump and motor are in the fryer cabinet. Micro-Flo Filters (MF-90 Series) BUILT-IN FILTER SYSTEMS (BI) Micro-Flo filter systems are very similar to the Frymaster Filter Magic system.
Portable Filtration Systems Portable filters are manufactured as suction/return or suction-only models. The more common type is the “suction/return” unit. The motor/pump is reversible and allows use of the filter with all fryers with or without a front oil drain. The control switch has three positions: IN— OFF— OUT. “Return-only” models are exclusively for gravity-draining fryers. The control switch has two positions: OFF— RETURN.
Portable filter systems employ a hose/wand assembly to return filtered oil to the fry vessel. It is also used to rinse remaining sediment out the drain valve to prevent clogging and filteredoil contamination. Suction/Return units also use the hose to suck the oil out of the vessel. When using the suction feature of a portable filter system, it is essential to keep the tip of the filter hose wand out of the sediment in the bottom of the fryer.
5. If time permits, dampen the powder with hot oil (either by draining some out of the first vessel or by scooping some out of a vessel) and turn the filter pump on momentarily. This ensures a good seal between the paper and the filter screen/grid. 6. Proceed with normal filtration operation. 7. If filtration seems slow after filtering two or three vats, inspect the paper. Clean off excess sediment build-up, or replace top sheet of paper if necessary.
Wiring Diagrams Super Cascade Filter 120VAC Power Supply WHT BLK GND WHT WHT BLK PUR BLK To LH Fryer Circuit BRN RED YEL Fuse Fuse RED BRN BRN CB ORG 120VAC/12VAC Transformer WHT BLU Circuit Breaker Fuse 20 Amp BLK YEL PUR YEL 120V Manual Bypass Switch BLU WHT ORG RED 12V To Fryer Controls 120VAC/12VAC Transformer RED 24V 120V RED NC NO COM BLU NC NO COM YEL YEL YEL DPDT 24VAC Relay PUR RED YEL#1 YEL YEL RED DPDT 24VAC Relay 24V BLU 24V YEL YEL#1 PUR YEL RED 2 1
Wiring Diagrams (cont.) Cascade Filter with Heater BLK 7 Amp Circuit Breaker GRN WHT 120VAC Power Supply CB Heater ON Pump ON T5 T4 SPDT Toggle Switch Probe Heater T1 T8 Motor Terminal Box MF90-BI with Heater HG N BLK 3 5 2 WHT Ind. Light WHT BLK 6 BLK Ind.
Wiring Diagrams (cont.) MF90-BI without Heater HG N WHT GRN BLK Power Switch 6 3 5 2 4 1 WHT BLK WHT BLK#1 Ind.
Wiring Diagrams (cont.
Troubleshooting 1. Filter-pump motor stopped suddenly or doesn’t run at all. a. b. c. d. Turn unit OFF. Reset wall circuit breaker. Press filter reset button. If motor repeatedly stops, check for blockages in filter pump. 2. Motor fails to run after blockages have been cleared. a. Reset internal filter pump circuit breaker. b. Faulty pump motor. 3. Rate of oil return to the fryer is slowing. a.
