Instruction/ maintenance manual of the product Dean FPHD Frymaster
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Dean, a member of the Comm ercial Food Equipm ent Service Association, rec ommends using CFESA Certified Technicians. PRINTED IN THE UNITED STATES OF AMERICA 24-Hour Service Hotline 1-800-551-8633 MAY.
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.
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.
Decathlon Series Gas Fryers Service and Parts Manual TABLE OF CONTENTS 1. SERVICE PROCEDUR ES ……..……..……………………………………………... 1.1 Functional Description................................ ...........................
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-1 High efficiency burner and diffuser. 1.1 Functional Description High Efficiency Decathlon ( HD) Series gas fryers contain a welded stainless steel frypot heated by gas flames diffused evenly th rough tubes bui lt into the frypot.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-2 1.1 Functional Description (cont.) Pilot System Configuration The pilot system is comprised of the pilot orif ice, pilot hood, and a therm opile (some systems incorporate a thermocouple).
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-3 Electronic Igniti on 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 computer and to one si de of the heat relay co il on the interface board.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-4 Interface Boards (cont.) 826-2086 (115/230V): These boards are used in HD fryers equipped with Thermatron control systems. Thermatron systems incorporate a tem perature probe , a potentiometer, and a temperature co ntrol circuit board.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-5 Interface Boards (cont.) 826-2434: These interface boards are used in HD fr yers equipped with e lectronic ign ition and constant pilot. INTERFACE BOARD P/N 106-6669 (Kit 826-2434 ) Used on fryers equipped with electro nic ignition and constant pilot.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-6 Interface Boards (cont.) FREQUENTLY USED TEST POINTS FOR HIGH EF FICIENCY DECATHLON (H D) FRYERS 106-6669 INTERFACE BOARD .
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-7 Thermostats Different types of thermostats ar e used in High Efficiency Decathl on Series gas fryers, depending on fryer configuration. Fryers equipped with a Thermatron use a dial to adjust temperature.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-8 Restraints Once the fryer has been positioned at the frying stat ion, use a carpenter’s level p laced across the top of the frypot to verify that the unit is le vel, both side-to-side and front-to-back.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-9 1.3 Cleaning the Gas Valve Vent Tube (if applicable) 1. Set the fryer power switch and th e gas valve to the OFF position. 2. Carefully unscrew the vent tube from the gas valve.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-10 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.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-11 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.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-12 1.7.3 Replacing the Temperature Probe; Computer-equipped Fryers 1. Disconnect the fryer from the electrical supply. 2. Drain cooking oil from th e frypot. Allow the frypot to cool c ompletely befor e proceedi ng.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-13 1.7.3 Replacing the Temperature Probe; Computer-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.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-14 1.7.3 Replacing the Temperature Probe ; Computer-equipped Fryers (cont.) 10. Locate the temperature probe inside th e frypot. Remove the temperature probe mounting hardware.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-15 Installing the New Temperature Probe: 1. Feed the probe wire through the probe ni pple from the top side of the frypot. 2. Loosely install the bladder nut. 3. Mount the probe into the mounting hardware.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-16 1.7.4 Replacing the High-limit Thermostat (cont.) 6. Locate the high-limit probe inside the frypot. Remove the high-limit probe mounting hardware. Retain mounting hardware f or installation of new temperature probe 7.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-17 1.7.4 Replacing the High-limit Thermostat (cont.) 8. Mark and disconnect wires at the high-limit in the component box. 9. Remove high-limit f rom fryer by pulling the capillary tube and bulb through the component box opening (arrow).
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-18 1.7.5 Replacing Rocker Switches 1. Disconnect the fryer from the electrical supply. 2. If switches are located in a control box within the fryer , remove the six screws securing the switch panel to the control box.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-19 1.7.5 Replacing Rocker Switches (cont.) 3. Depress the retaining clips (see illustration below ) and push the switch out of the slot. If there is a switch-guard present, retain it f or installation of the replacem ent switch.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-20 1.7.7 Replacing the Pilot Assembly 1. Remove the pilot tubing from th e bottom of the pilot assembly. 2. If the pilot is an electronic ignition pilot, disconnect the i gnition cable and the sense wire.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-21 1.7.8 Replacing the Frypot (cont.) 6. Remove the top cap. It is held in place by one screw on each side of the fryer. If the fryer has a controller on the front, the top cap may also be held in place by two screws on the front of each pot.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-22 1.7.8 Replacing the Frypot (cont.) 10. Remove screws securing flue cap to frypot (access from above; a nut-driver with an extension or long screwdriver is required). Use care not to drop the screws into the flues.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-23 1.7.8 Replacing the Frypot (cont.) 12. Remove screws securing flue to frypot (access from above; a nut-driver with an extension or long screwdriver is requi red). Retrieve any screws dropped into the flue during removal of the flue cap and frypot bracket.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-24 1.7.8 Replacing the Frypot (cont.) 15. Remove the drain manifold. Only the drain tubes directly blocking the frypot being replaced require removal. - Remove the nuts holding the drain valve strap onto the drain tube stud.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-25 1.7.8 Replacing the Frypot (cont.) 19. If the fryer is equipped with drain-valve mi croswitches, m ark the wires and microswitch terminals, then disconnect wires from the switch.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-26 1.7.8 Replacing the Frypot (cont.) 22. Remove the temperature probe from frypot. (See Section 1.7.3, Replacing the Temperature Probe: Computer–equipped Fryers , for specific instructions.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-27 1.7.8 Replacing the Frypot (cont.) 26. Ensure wires and tubes will not be caught on the frypot when it is removed. 27. Remove frypot from fryer by lifting up and out. 28. Position the frypot upside down on a suitable work surface.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-28 1.8 Troubleshooting and Problem Isolation Because it is not feasible to include every issue that m ight occur, this secti.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-29 1.8.1 Ignition Failure (cont.) The Electronic Circuits If gas and electrical power are supplied to the fryer, the next mo.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-30 1.8.2 Improper Burner Function (cont.) If popping occurs only during peak operating hours, th e problem may be incorrect or fluctuating gas pressure.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-31 1.8.2 Improper Burner Function (cont.) Burners lighting on the left side only m ay be caused by a trailing pi lot problem (four- and five-tube frypots) or improper burne r manifold pressure.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-32 1.8.4 Improper Computer Function Sensitivity or "Stretch Time." Sensitivity—or stretch tim e—is a programmable feature that increases the cook time countdown based on variations in the oil temperature from the setpoint (e.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-33 1.8.5 Improper Filtration Function The majority of filtratio n problems arise from operator error. One of the m ost common errors is placing the filter paper on the bottom of the filter pan rather than over the filter screen.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-34 1.8.5 Improper Filtration Function (cont.) Incorrectly sized or installed pa per will allow food particles and se dim ent to pass through and clog the suction tube on the bottom of the filter carr iage.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-35 1.8.7 Improper Basket Lift Function Bell-Crank Basket Lifts Most High Efficiency Decathlon Series gas fryers are equipped with a bell-crank style basket lift. A cam and a bell crank are connected to the basket lift arm by a flat metal link.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-36 1.9 Troubleshooting Guides The following troubleshooting guides are intended to assist service technicians in quickly isolating the probable causes of equipment malfunctions by following a logical, step-by-step process.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-37 1.9 Troubleshooting Guides (cont.) C. Gas valve is known to be good, but there is not 24 VAC (120VAC on systems so equipped) at the gas valve terminals. D. Inspect electronic sensor (while still in frypot) for damage.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-38 1.10 Wiring Diagrams Note: The diagrams in this section depict wi ring as of the date of manual publication. It may not reflect design changes made to the equipment after publication.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-39 Computer with Constant Pilot.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-40 CM4-S Wiring.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-41 Dean Oil Return Wiring.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-42 Dean Oil Return Wiring, with S olenoid.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-43 1.11 Probe Resistance Charts Thermatron Probe Re sistance Chart ° Celsius ° Fahrenheit Ohms (±3% ) 21 70 108130 27 80 .
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-1 2.1 High Efficiency Decathl on (HD) Primary Components 9 32 6 24 1 20 21 25 7 8 5 3 2 10 19 18 17 4 22 25 28 16 29 15 14 13 12 31 .
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-2 Parts are label ed to indicat e the appr opriate fryer m odel (“HD”, “SC FHD”, or “FP HD65”). If a part is n ot labeled, it can be used on any of t hese models. Each sect ion is labe l ed by size (e.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-3 2.1.1 Decathlon HD50 Primary Components (includes SCFHD units ) (cont.) ITEM PART # COMPONENT * 231-2060 Side Panel, Left Side (SC.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-4 2.1.2 Decathlon HD60 Primary Components (includes SCFHD units) ITEM PART # COMPONENT 1 823-4692 Frypot - S/S (SCFHD) * 823-5742 Fr.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-5 2.1.2 Decathlon HD60 Primary Components (includes SCFHD units ) (cont.) ITEM PART # COMPONEN T 14 211-4570 Side Panel, Left Side (.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-6 2.1.2 Decathlon HD60 Primary Components (includes SCFHD units ) (cont.) ITEM PART # COMPONENT 24 810-0180 Handle, Door, Wireform 2.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-7 2.1.3 Decathlon FPHD65 Primary Components (co nt.) ITEM PART # COMPONENT 10 807-3552 Gas Valve, Natural Gas, Electronic Ignition, .
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-8 2.1.3 Decathlon FPHD65 Primary Components (co nt.) ITEM PART # COMPONENT 21 Flue Cap 230-2473 x1 230-2298 x2 230-2323 x3 230-2344 .
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-9 2.2 Orifices ITEM PART # COMPONENT Natural Orifices * 810-2938 0-1999 ft. * 810-3053 2000-3999 ft. * 810-3054 4000-5999 ft. * 810-3055 6000-7999 ft. * 810-3056 8000-8999 ft. * 810-3057 9000-10000 ft.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-10 2.3 Control Panel Options, Joiner Strips, and Accessories ITEM PART # COMPONENT Control Pa nels 1 210-3562 Controller, x1 (HD150,.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-11 2.4 Optional Components and Controllers ITEM PART # COMPONENT 1 826-2013 Thermostat, Sunne 2 810-2035 Knob, Thermostat 3 826-2117.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-12 2.4 Optional Components and Controllers (cont.) ITEM PART # COMPONENT * 106-1238 Pilot Assembly (w ithout computer), Natural * 80.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-13 2.4 Optional Components and Controllers (cont.) ITEM PART # COMPONENT * 807-3559 High-limit Thermostat, Manual Reset 435° F (pre.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-14 2.5 3” Oil Drain Manifold, Drain Flush, and Drain Valve Components.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-15 2 . 5 3” Oil Drain Manifold, Drain Flush, and Dr ain Valve Components (cont.) ITEM PART # COMPONENT 1 823-5880 Drai n Tub e, Do.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-16 2.6 Oil Return Manifold Components.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-17 2.6 Oil Return Manifold Components (cont.) ITEM PART # COMPONENT 106-4080 Oil Return Manifold, End (SCFHD50) 106-5616 Oil Return .
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-18 2.6 Oil Return Manifold Components (cont.) ITEM PART # COMPONENT * 813-0298 Nipple, 1 ⁄ 2 " x 2.00" NPT BM * 813-0098 Nipple, 1 ⁄ 2 " x 6.50" NPT BM * 813-0265 Nipple, 1 ⁄ 2 " x 2.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-19 2.7 Oil Re turn an d Oil Flush Components 14 9 15 16 13 19 18 11 17 10 12 3 2 4 5 6 8 1 7 20 22 21.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-20 2 . 7 Oil Return and Oil Flush Components (cont.) ITEM PART # COMPONENT 106-4006SP Microswitch Bracket Ass embly, Oil Return 1 90.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-21 2.8 Filtration Components 2.8.1 Filtration Components; SCFHD50 Series Fryers 3 5 8 6 7 1 4 2 9 ITEM PART # DESCRIPTION 106-514 4S.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-22 2.8.2 Filtration Components; SCF HD60 and SCFHD63 Series Fryers 3 5 1 6 7 2 4 8 9 ITEM PART # COMPONENT 106-7543 Filter Pan Assem.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-23 2.8.3 Filtration Components; FPHD65 Series Fryers 2 3 4 1 5 6 ITEM PART # COMPONENT 106-5081 Filter Pan Assembly (includes Items .
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-24 2.9 Basket Lift Components.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-25 2.9 Basket Lift Components (cont.) ITEM PART # COMPONENT 106-1870 Basket Lift Assembly (HD60) 1 823-3625 Basket Lift 2 809-0082 T.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-26 2.10 Trough, Holster, & Cover Components 1 2 3 4 ITEM PART # COMPONE NT 1 106-2668SP Holster Assembly, Vat Cover 2 823-338 4 .
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2: PARTS LIST 2-27 2.11 Fasteners (Screws, Nuts, Bolts) ITEM PART # COMPONENT * 809-0842 Nut, 4-40 Nylock * 809-0417 Nut, Flange 1 ⁄ 4 -20 Serrated * 809-0766 Nut, Keps 10-32 SS Hex * 826-1366 Nut, 4-40 Keps Hex w/External Teeth (pkg.
Dean, 8700 Line Av enue, PO Box 5100 0, Shrev eport, Louisiana 71135-1000 Shipping Address: 8700 Line Av enue, Shreveport, Louisiana 71106 TEL 1-318-865-1711 FAX (Parts) 1-31 8-688 -2200 FAX (Tech Sup.
An important point after buying a device Frymaster Dean FPHD (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Frymaster Dean FPHD yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Frymaster Dean FPHD - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Frymaster Dean FPHD you will learn all the available features of the product, as well as information on its operation. The information that you get Frymaster Dean FPHD will certainly help you make a decision on the purchase.
If you already are a holder of Frymaster Dean FPHD, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Frymaster Dean FPHD.
However, one of the most important roles played by the user manual is to help in solving problems with Frymaster Dean FPHD. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Frymaster Dean FPHD along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
