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High Efficiency Decathlon (HD)
Series Gas Fryers
Service & Parts Manual
HDC, CFHDC, SCFHDC,
FPHDC, Y/KSCF/C/HC, BK1814
(High Efficiency Common Cabinet
Decathlon Fryers)
Dean, a member of the Commercial Food Equipment Service Association, recommends using
CFESA Certified Technicians.
APRIL 2011
PRINTED IN THE UNITED STATES
24-Hour Service Hotline
*8196314*
OF AMERICA
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 AUTHORIZED SERVICE AGENCY. 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
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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 Frymaster and Dean Service Hotline at 1-800-551- 8633. This equipment is to be installed in compliance with the basic plumbing code of The Building
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High Efficiency Decathlon (HD) 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...................................................................................1-7 1.3 Cleaning the Gas Valve Vent Tube (if applicable)......................................
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FINDING YOUR WAY AROUND THE DEAN HIGH EFFICIENCY DECATHLON Basket Hanger Flue Cap Frypot Top Cap Electronic Operating Thermostat Controller Oil Return Handle Drain Tubes Drain Valve Handle (Red) Burners Filter Unit Gas Valve Oil Return Handle (Yellow) Drain Flush Handle (Blue) Note: The appearance of your fryer may differ slightly from that shown depending upon configuration and date of manufacture.
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1.1 Functional Description High Efficiency Decathlon (HD) Series gas fryers contain a welded stainless steel frypot heated by gas flames diffused evenly through tubes built into the frypot. Flames originate from orifices in a burner manifold positioned beneath cast-steel burners. The burners are positioned in the tube openings at the front of the frypot. The diameter of the orifices differs for natural
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1.1 Functional Description (cont.) Pilot System Configuration The pilot system is comprised of the pilot orifice, pilot hood, and a thermopile (some systems incorporate a thermocouple). The pilot serves two purposes: light the burner and heat the thermopile. In operation, the thermopile is in contact with the pilot flame and generates millivolts. The millivolt output energizes the gas valve pilot coil,
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES Electronic Ignition Configuration (cont.) 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 controller and to one side of the heat relay coil on the interface board. If resistance in the temperature probe indicates the temperature in the frypot is below 180°F (82°C), the current flows through a melt cycle circuit where a timer switc
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES Interface Boards (cont.) 106-3729 (24V): These boards are used in HD fryers equipped with Thermatron control systems. THERMATRON BOARD P/N 106-3729 Thermatron systems incorporate a temperature probe, a potentiometer, and a temperature control circuit board. This system is more accurate and reliable than a standard thermostat. The temperature probe measures oil temperature via resistance (ohms);
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES Interface Boards (cont.) 826-2434: These interface boards are used in HD fryers equipped with electronic ignition and constant pilot. INTERFACE BOARD P/N 826-2434 Used on fryers equipped with electronic ignition and constant pilot. 1-5
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES Interface Boards (cont.) FREQUENTLY USED TEST POINTS FOR HIGH EFFICIENCY DECATHLON (HD) FRYERS 106-6669 INTERFACE BOARD Test Meter Setting Pins Test Results 12VAC Power to Controller 50 VAC Scale 1 and 3 on J3 12-18 12VDC Power to Right BL Relay 50 VDC Scale 4 on J2 and 5 on J2 12-18 12VDC Power to Left BL Relay 50 VDC Scale 7 on J1 and 5 on J2 12-18 24VAC Power to High-Limit 50 VAC Scale 6 on J2 and GROUND
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES Thermostats Different types of thermostats are used in High Efficiency Decathlon Series gas fryers, depending on fryer configuration. Fryers equipped with a Thermatron use a dial to adjust temperature. In this configuration, the probe resistance varies inversely with the temperature. As the temperature rises, resistance decreases at a non-linear rate. A chart is located at the end of this chapter. Frye
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HIGH EFFICIENCY 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
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HIGH EFFICIENCY 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 wire through the tube to remove any obstruction. Remove the wire and blow through the tube to ensure it is clear. 4. Reinstall tube and bend so t
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HIGH EFFICIENCY 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
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1.7 Replacing Fryer Components 1.7.1 Replacing the Controller 1. Disconnect the fryer from the electrical supply. 2. Unscrew the two controller panel screws. The controller 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 controller. 4. Remo
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1.7.2 Replacing the Temperature Probe; Controller-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 fryer door for easier access to the temperature probe. First, remove top hinge from bracket. Then, lift door off bottom hinge pin. Remove the fryer door for easier access to
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1.7.2 Replacing the Temperature Probe; Controller-equipped Fryers (cont.) 6. Remove the burner shield by loosening the screw on each end. 7. Remove the burner rail by loosening the screw on each end. The burner rail secures the burners in the burner manifold. Be careful to ensure that the burners do not fall out of the gas manifold, as they might be damaged and dented. Remove the burner rail a
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1.7.2 Replacing the Temperature Probe; Controller-equipped Fryers (cont.) 10. Locate the temperature probe inside the frypot. Locate the temperature probe. 11. The temperature probe can be removed through the bottom of the frypot as follows: Ensure the two-pin connector has been removed from the probe wiring harness (step 4, above). Carefully bend the two tabs (one f
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES Installing the New Temperature Probe: 1. Feed the probe wire through the probe nipple from the top side of the frypot. 2. Loosely install the bladder nut. 3. Mount the probe into the mounting hardware. Carefully bend the two tabs back into alignment to retain probe. 4. Tighten the bladder nut. 5. Install the insulation and plug. 1.7.3 Replacing the High-limit Thermostat 1. Turn fryer off
