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Decathlon Series Gas Fryers
Service & Parts Manual
D, CFD, SCFD, FPD,
and Common Cabinet Models
NON-CE &
Dean, a member of the Commercial Food Equipment Service Association, recommends using
CFESA Certified Technicians.
FEBRUARY 2007
24-Hour Service Hotline
*8195922*
1-800-551-8633
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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 FRYMASTER FACTORY AUTHORIZED SERVICE CENTER. 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
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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. 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. WARNING No structural material on the fryer should be altered or removed to accommodate placement of the fryer under a hood. Questions? Call the
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Decathlon Series Gas Fryers Service and Parts Manual TABLE OF CONTENTS 1. SERVICE PROCEDURES……..……..……………………………………………... 1.1 Functional Description............................................................................................1-1 1.2 Accessing Fryers for Service...................................................................................1-8 1.3 Cleaning the Gas Valve Vent Tube (if applicable)..............................................1-10 1.4 Ad
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FINDING YOUR WAY AROUND THE DEAN DECATHLON Basket Hanger Flue Cap Frypot Top Cap Electronic Operating Thermostat Burners Drain Tubes Drain Valve Handle (Red) Filter Unit Oil Return Handle (Yellow) Drain Flush Handle (Blue) Drain Tubes
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DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1.1 Functional Description Decathlon Series gas fryers contain a welded steel frypot (stainless or cold-rolled) heated by gas flames diffused evenly through tubes built into the frypot. Flames originate from orifices in a burner manifold positioned beneath cast-iron burners. The burners are positioned in the tube openings, at the front of the frypot. The diameter of the orifices differs for natural (CE:G20/G25) and LP
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DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1.1 Functional Description (cont.) An electromechanical gas valve regulates gas flow to the manifold. Decathlon Series gas fryers are equipped with either a 120V valve system or a 24V valve system. Unit configurations include either a pilot ignition system (standing pilot) or an electronic ignition system. Pilot System Configuration The pilot system is comprised of the pilot orifice, pilot hood, and a thermopile. Th
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DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES Electronic Ignition Configuration (cont.) The module contains a 60-second time delay circuit and a coil that activates the gas valve. The ignitor assembly consists of a spark plug, a pilot, and a flame sensor element. At start-up the ON/OFF switch is placed in the ON position, supplying 12 VDC to the heat control circuitry in the controller or computer and to one side of the heat relay coil on the interface board. If res
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DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES Interface Boards The interface board provides a link between the controller/computer and the fryer’s individual components without requiring excessive wiring, and allows the controller to execute commands from one central point. Two types of interface boards may be used in Decathlon Series gas fryers; the type used depends on the fryer configuration. In units configured for Thermatron, P/N 826-2086 (115/230V) is used; in
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DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES Interface Boards (cont.) IFB 106-6669 & 106-6710: These interface boards are used in Decathlon fryers with Frymaster computer control systems. INTERFACE BOARD P/N 106-6669 INTERFACE BOARD P/N 106-6710 FREQUENTLY USED TEST POINTS FOR INTERFACE BOARD P/N 806-4549 (previous style) Test Meter Setting Pins Test Results 12VAC Power to Controller 50VAC Scale 1 and 3 on J3 12-18 24VAC Power to Right Module
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DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES Interface Boards (cont.) P/N 806-4549 INTERFACE BOARD (previous style) LED DIAGNOSTIC LIGHTS 12V Indicates 12 VAC from transformer 24V Indicates 24 VAC from transformer GV Indicates 24 VAC to gas valve PWR Indicates 24 VAC to PWR via K1 (L) or K2 (R or F) AIR Not Applicable to Decathlon Series Gas Fryers The board contains two heat relays (K2 and K3), and two basket lift relays (K1 and K4). NOTE: On factory-origina
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DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES Thermostats Different types of thermostats are used in Decathlon Series gas fryers, depending on fryer configuration. Fryers equipped with an optional backup operating-thermostat and/or Thermatron use a dial to adjust temperature. In this configuration, the probe resistance varies directly with the temperature. As the temperature rises, resistance decreases at a rate of approximately 2 ohms for every 1°F (approximately
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DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES Restraints Once the fryer has been positioned at the frying station, use a carpenter’s level placed across the top of the frypot to verify that the unit is level, both side-to-side and front-to-back. To level fryers equipped with legs, the bottom of the legs can be screwed out up to one inch for leveling. Legs should also be adjusted so that the fryer(s) are at the proper height in the frying station. For fryers equipp
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DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1.3 Cleaning the Gas Valve Vent Tube (if applicable) 1. Set the fryer power switch and the gas valve to the OFF position. 2. Carefully unscrew the vent tube from the gas valve. NOTE: The vent tube may be straightened for ease in removal. 3. Pass a piece of ordinary binding wire (.052 inch diameter) through the tube to remove any obstruction. Remove the wire and blow through the tube to ensure it is clear. 4. Reinst
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DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1.5 Adjusting the Pilot Flame 1.5.1 Main Pilot 1. Remove the cap from the pilot adjustment screw hole on the gas valve. 2. Using a small, flat-tipped screwdriver, turn the pilot adjusting screw counterclockwise to increase length of flame or clockwise to decrease length of flame. Adjust to obtain a flame from 1 inch to 1½ inches long. 3. Reinstall the pilot adjustment screw cap. 1.5.2 Trailing Pilot In old
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DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1.6.2 Backup Operating Thermostat (Optional) 1. Fill the frypot to the lower OIL-LEVEL line with oil. If solid shortening is used, it must be melted before starting the calibration procedure. 2. Light the pilot. 3. Set the temperature control knob to 350°F/177°C. 4. Let the burners cycle on and off automatically three times in order for the cooking oil temperature to become uniform. If necessary, stir to get all sh
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DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1.7 Replacing Fryer Components 1.7.1 Replacing the Computer 1. Disconnect the fryer from the electrical supply. 2. Unscrew the two computer panel screws. The computer panel is hinged at the bottom and will swing open from the top. Computer panel in “down” position. 3. Unplug the fryer wiring harness and ground wire from the back of the computer. Disconnect the 15-pin
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DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1.7.2 Replacing the Backup Thermostat (if applicable) 1. Disconnect the fryer from the electrical supply. 2. Drain cooking oil from frypot. 3. Remove thermostat knob. 4. Disconnect the wiring plug(s) from the component shield/control box. 5. Disconnect leads from terminal block. 6. Remove screws securing the thermostat bracket to fryer. 7. Follow Steps 5-7 in Section 1.7.4, Replacing the High-limit Thermostat
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DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1.7.3 Replacing the Temperature Probe; Computer-equipped Fryers 1. Disconnect the fryer from the electrical supply. 2. Drain cooking oil from the frypot. Allow the frypot to cool completely before proceeding. 3. Remove the fryer door for easier access to the temperature probe. D models: Lift door up, disengage rod from lower door bracket, and remove door. CFD/SCFD/FPD models: Remove the top bracket and hinge, the
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DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1.7.3 Replacing the Temperature Probe; Computer-equipped Fryers (cont.) 6. Remove the appropriate burners to gain access to the temperature probe. (See Steps 20-22 on page 1-27 for more details.) NOTE: Ensure that the burners are placed in their original spots when putting them back into the fryer. (See page 1-28.) Remove burners to gain access to temperature probe. 7. Loosen and unscrew the
