Decathlon Series Gas Fryers Installation, Operation & Maintenance Manual D20, D50, D60 & D80 Series Dean, a member of the Commercial Food Equipment Service Association, recommends using CFESA Certified Technicians. 24-Hour Service Hotline 1-800-551-8633 Price: $8.
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. CAUTION Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other cooking appliance.
Decathlon Series Gas Fryers TABLE OF CONTENTS Page # 1. INTRODUCTION 1-1 2. IMPORTANT INFORMATION 2-1 3. INSTALLATION INSTRUCTIONS 3-1 4. FRYER OPERATIONS 4-1 5. COMPU-FRY/THERMATRON INSTRUCTIONS 5-1 6. PREVENTATIVE MAINTENANCE 6-1 7. TROUBLESHOOTING 7-1 8.
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.
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. 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. DANGER Hot cooking oil causes severe burns.
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.
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 designcertified for the following installations: 1.
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. Do not connect this fryer to an exhaust duct. B. Correct installation and adjustment will ensure adequate airflow to the fryer system. C. A commercial, heavy-duty fryer must vent its combustion wastes to the outside of the building.
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.
DECATHLON SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.1 Installing the Fryer A. 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. B. Relocating the fryer: Remove all weight from each leg before moving a fryer with legs installed. Do not slide the fryer on the legs. C.
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.
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 threads.
3.5 Gas Connections (cont.) 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.
3.5 Gas Connections (cont.) J. After hook-up, bleed the gas line of air to ensure that the pilot light will ignite quickly. K. 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 national standard). 3.6 Adjustments/Adaptation To Different Gases A.
3.6.1.2 Adjustments to Different Gas Types Gases and Gas Supply Pressure* G20 20 mbar G25 25 mbar G31 37/50 mbar Orifice Diameter 2.40 mm 2.40 mm 1.51 mm Burner Marking "blue" marking "blue" marking TJ024 TJ024 "red" marking TJ013 "red" 10 15 Pilot Marking Gas pressure at regulator (mbar)* the 27 NOTE: Outlet gas pressure must be adjusted strictly within the above requirements 5 to 10 minutes after the appliance is operating.
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.
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 QTY REF DESCRIPTION 1 TJ013 Pilot orifice 5 14-0067-2Red Burner orifice (diameter: 1.
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). 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.
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.
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.
4.1.2 Pilot Lighting Procedures, Electronic Ignition Systems (cont.) 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.
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. 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.
4.2.2 Filtration/Boil-Mode Option-Equipped Fryers (cont.) 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 be performed each time the oil/shortening is changed. 4.2.3 Computer-Equipped Fryers A.
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.
DECATHLON SERIES GAS FRYERS CHAPTER 5: COMPU-FRY/THERMATRON INSTRUCTIONS 5.1 Operating Fryers with Dean Compu-Fry Computers 1 4 6 3 8 2 5 7 ITEM 1 DESCRIPTION Lighted Display -- left display of various functions and operations. 2 Lighted Display -- right display of various functions and operations. 3 Program Lock and Temperature Check Switch -- locks program in computer and/or displays frypot temperature when depressed.
5.1 Operating Fryers with Dean Compu-Fry Computers (cont.) 5.1.1 Equipment Setup and Shutdown Procedures Setup WARNING Fill the frypot to the bottom OIL LEVEL line with vegetable oil before pressing the ON/OFF switch to the "ON" position. Failure to do so could damage the frypot. 1. 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.
5.1.1 Equipment Setup and Shutdown Procedures (cont.) " indicating that the fryer temperature is in the cooking range. NOTE: For best d. " results, do not cook product until the display reads " ". e. , 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. , indicates that the computer has detected a problem in the temperature measuring circuits, including probe. NOTE: ".
5.1.2 Checking Temperature A. Check the cooking oil/shortening temperature at any time by pressing the Check the setpoint by pressing the switch twice. switch once. B. 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. C.
5.2 Programming The Dean Compu-Fry Computer (cont.) 7. 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. now appears in the left display. The previous shake time (if any) will appear in the right display.
5.2 Programming The Dean Compu-Fry Computer (cont.) 15. 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. 16.
5.2.2 Fryer Recovery Time Check 1. To check recovery time, press the 2. Enter displays for 5 seconds. 5.2.3 switch. will appear in the left display. (1 6 5 2) in that sequence. The recovery time will appear in both 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 the switch. will appear in the left display. (1 6 5 8) in that sequence.
5.3 Operating Fryers with Thermatron Controllers Fryer Power Switch: controls power to each individual fryer, both in Thermatron or Back-up mode. POWER O F F Main Power Switch: connects/disconnects primary power; doublelighted with center position "OFF". This switch controls two Thermatron controllers and/or two back-up thermostats. O N B ON OFF ON A T C K M T U P MAIN POWER O F F O N O N O F F O F F BOIL OUT O F F Filter Power Switch: connects/ disconnects power to filter pump.
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.
DECATHLON SERIES 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.
6.1.4 Stainless Steel Care 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 liquid 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.
DECATHLON SERIES GAS FRYERS CHAPTER 7: TROUBLESHOOTING 7.1 General 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.
7.2 Pilot Burner Malfunction (cont.) C. Pilot flame of proper size, but is unstable. thermocouple completely at all times. Flame wavers and does not envelop the 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. CAUTION Do not attempt to turn the adjustment past the stops or the controller will be damaged. 7.3 Main Burner Malfunctions A. Main burner will not come “ON”; gas not detected at main burner. 1.
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.
7-4 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 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 RELAY R1 120 VAC 4 2 31 POWER SWITCH 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
ORG 7-5 WHT SENSOR N. Open Common WHT ORG WHT BLUE BRN WHT Temperature Sensor 1 2 3 4 5 6 7 8 9 V2D L PWR J1 2 WHT BLK GRN 1 2 3 4 5 6 7 8 9 MV/PV CND PV MV SEN. TH IGN TR ORG 1 2 WHT 1 2 ORG PURP M T LED 2 L-HEAT 14 14 15 A RL-1 6 6 J1 YEL 8 LED 1 L-GV 7 ON/OFF POWER 2 2 1 1 LED 6 12V 3 3 3 12 VAC 5 1 115 VAC BRN RED YEL 5 ON/OFF POWER 5 AIR LED 3 24V R-GV LED 5 8 7 YEL 115 VAC J3 BRN BRN YEL BRN YEL C.B.
2 V2D L PWR J1 7-6 M T L-HEAT LED 2 14 14 15 15 4 LEFT TEMP PROBE A 6 6 RL-1 LINE VOLTAGE 8 C 2 3 ON/OFF POWER 2 1 1 LED 6 1 LED 1 5 12V 7 12V L-GV R1 NC NO 3 3 C ON/OFF POWER 5 5 AIR LED 3 24V R-GV LED 5 8 24V 7 R2 NC NO A 4 4 RL-3 13 13 14 14 10 F1 M T 11 11 R-HEAT LED 4 HEAT 2 4 J3 J2 V1D R PWR RIGHT TEMP PROBE SD Sound: Terminal #1 - Loud Terminal #2 - Medium Terminal #3 - Low Sound Device V2D RL2 RL4 V1D J3 To Terminal
POWERSWITCH 220 VAC POWER SUPPLY Temperature Sensor FUSE 2 AMP 1 2 1 2 24 VAC 7-7 12 34 12 34 POT 230 VAC 13 2 14 3 7 8 9 10 11 12 1 12 345 6 78 9 12 3456 48 OHM RESISTOR 12 3456 78 9 24VAC COIL 24VAC COIL HIGH-LIMIT THERMOSTAT 24V "G0" SOLID STATE TEMPERATURE CONTROLLER DRAIN VALVE SAFETY SWITCH 1 2 34 56 OPTIONAL BOILOUT THERMOCOUPLE SOLDER CONNECTION ECO CONNECTOR ASSEMBLY G31 GAS (LP GAS) G20, G25 GAS (NAT.
DECATHLON SERIES GAS FRYERS CHAPTER 8: PARTS LIST 22 26 24 30 1 6 25 10 9 11 7 21 8 4 32 5 2 16 35 3 20 12 17 15 Controllers, probes and related/optional components are listed in Optional Components, Controllers and Related Components, Section 8.
8.
8.1 Decathlon D-20 Primary Components (cont.) ITEM 31 32 * * 33 34 35 PART # 11-0140-2 N/A 07-0139 07-0140 1731-2 14169 07-0006 COMPONENT Cover, Outlet Duct Rear Panel Structural Back Upper Structural Back Lower Structural Back Leg (Black) Leg Support Assembly Burner Mounting Bracket 8.
8.2 Decathlon D-50 Primary Components (cont.
8.3 Decathlon D-60 Primary Components (cont.
8.
8.4 Decathlon D-80 Primary Components (cont.) ITEM 31 32 * * 33 34 35 PART # 11-0140-2 80-0050 N/A N/A 1731-2 12085 18-0072 COMPONENT Cover, Outlet Duct Rear Panel Structural Back Upper Structural Back Lower Structural Back Leg (Black) Leg Support Assembly Burner Mounting Bracket 8.5 Optional Components, Controllers and Related Components (CE and Domestic)* * Components are applicable to all Decathlon Fryers covered in this manual unless otherwise noted.
8.5 Decathlon Component Options (CE and Domestic, cont.
Dean, 8700 Line Avenue, Shreveport, Louisiana 71135 TEL 1-318-865-1711 PRINTED IN THE UNITED STATES FAX (Parts) 1-318-219-7140 SERVICE HOTLINE 1-800-551-8633 (Tech Support) 1-318-219-7135 Price: $8.
