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Frymaster Dean FPHD, Service & Parts Manual

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Frymaster Dean FPHD Service & Parts Manual Download Page 23

 

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.  Do not allow the switch panel to hang from the switch wiring 
harness or other wires.  (Figure B) 

 

Remove the screws holding the plate in place, then depress the 
clips on each end to remove the switch.

FIGURE B

Remove six screws.

 

 

Summary of Contents for Dean FPHD

Page 1: ...using CFESA Certified Technicians PRINTED IN THE UNITED STATES OF AMERICA 24 Hour Service Hotline 1 800 551 8633 MAY 2007 8196314 High Efficiency Decathlon HD Series Gas Fryers Service Parts Manual De...

Page 2: ...ational Fuel Gas Code ANSI Z223 1 The Natural Gas Installation Code CAN CGA B149 1 The Propane Installation Code CAN CGA B149 2 or The latest edition of the National Electric Code N F P A 70 NOTICE If...

Page 3: ...al apparatus does not exceed the Class A or B limits for radio noise emissions as set out by the ICES 003 standard of the Canadian Department of Communications Cet appareil numerique n emet pas de bru...

Page 4: ...8 Troubleshooting and Problem Isolation 1 28 1 9 Troubleshooting Guides 1 36 1 10 Wiring Diagrams 1 38 1 11 Probe Resistance Charts 1 43 2 PARTS LIST 2 1 Decathlon Primary Components 2 1 2 2 Orifices...

Page 5: ......

Page 6: ...penings at the front of the frypot The diameter of the orifices differs for natural and LP gas as indicated in the accompanying table GAS INFORMATION Altitudes of 2000 feet or less EQUIPMENT PRESSURE...

Page 7: ...ve closes The main valve of the gas valve will not open if the pilot valve is not open The pilot flame must be manually lit when the fryer is first placed into operation A separate 24V circuit activat...

Page 8: ...opening and the ignition module locks out until the power switch is turned OFF then back ON A temperature probe monitors the temperature in the frypot When the programmed setpoint temperature is reach...

Page 9: ...r 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 as oil temperature ris...

Page 10: ...ICE PROCEDURES 1 5 Interface Boards cont 826 2434 These interface boards are used in HD fryers equipped with electronic ignition and constant pilot INTERFACE BOARD P N 106 6669 Kit 826 2434 Used on fr...

Page 11: ...To 24VAC Gas Valve 50 VAC Scale 7 on J2 and GROUND 22 28 Probe Resistance R x 1000 Ohms 10 and 11 on J2 Disconnect 15 pin harness from controller before testing probe circuit See Probe Resistance Char...

Page 12: ...d by means of a keypad on the face of the computer All HD Series gas fryers are equipped with a high limit thermostat In the event that the fryer fails to control the oil temperature the high limit th...

Page 13: ...tion Install the restraints in accordance with the provided instructions see illustration below If the restraints are disconnected for service or other reasons they must be reconnected before the frye...

Page 14: ...task should be performed by qualified service personnel only 1 Ensure that the gas valve knob is in the OFF position 2 Remove the pressure tap plug from the gas valve see arrows in photos below for l...

Page 15: ...itch is in the OFF position and light the pilot 3 Place the fryer ON OFF switch in the ON position Set the potentiometer dial to 325 F 162 C 4 Allow the oil to equalize at setpoint temperature This is...

Page 16: ...panel screws The computer panel is hinged at the bottom and will swing open from the top 3 Unplug the fryer wiring harness and ground wire from the back of the computer 4 Remove the computer by lifti...

Page 17: ...w probe 5 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 Disconnect t...

Page 18: ...the burners to gain access to the temperature probe and to ease frypot removal Lean each burner slightly away from the frypot to clear the burner seal metal box attached to frypot Then pull the burner...

Page 19: ...ough the frypot from the bottom complete step 7 above prior to removing probe 12 Carefully remove the probe from the frypot As the probe is removed tilt the probe at an angle to facilitate removal cur...

Page 20: ...he frypot to cool completely before proceeding 2 Perform steps 1 4 in Section 1 7 1 Replacing the Computer 3 Remove fryer door for easier access to the temperature probe First remove top hinge from br...

Page 21: ...e high limit probe inside the frypot Remove the high limit probe mounting hardware Retain mounting hardware for installation of new temperature probe 7 Carefully pull high limit capillary tube and bul...

Page 22: ...ing arrow This may require removal of the control panel frame 10 Reverse the above steps for high limit installation IMPORTANT When installing new high limit ensure the capillary tube and bulb are pos...

Page 23: ...upply 2 If switches are located in a control box within the fryer remove the six screws securing the switch panel to the control box Do not allow the switch panel to hang from the switch wiring harnes...

Page 24: ...ceeding further 1 Disconnect fryer from electrical and gas supplies 2 Disconnect the wires from the gas valve terminal block marking each wire to facilitate reconnections For 120VAC gas valves disconn...

Page 25: ...prior to moving fryer DANGER Hot cooking oil will cause severe burns Never attempt to move this appliance when filled with hot cooking oil or to transfer hot cooking oil from one container to another...

Page 26: ...ner strips on either side of the frypot Be careful not to bend the joiner strip during removal 8 Remove back panels of the fryer There may be both upper and lower panels and several screws secure them...

Page 27: ...g edge There will be two or three screws depending on configuration view from above looking down into flue Remove the screws arrows securing the flue cap to the frypot on the short edge There will be...

Page 28: ...n valve at the rear of the fryer Slip Section A of the clevis clip off of the oil return handle by pulling up on the rings Slide the oil return handle out of the bracket and Section B of the clevis cl...

Page 29: ...g the oil return line to the bottom of the frypot at the rear of the fryer using a wrench This may require removal of other pieces of the oil return manifold as needed 17 Remove the burner shield by l...

Page 30: ...re Depending on placement and configuration the valve may be turned in a different direction than pictured 21 Remove the pilot assembly from the frypot If trailing pilot disconnect the pilot supply li...

Page 31: ...instructions 23 Remove the high limit from the frypot 24 Remove bolts from brackets securing burner manifold to frypot Leave the manifold in place 25 Using a sharp knife or box cutter cut the silicon...

Page 32: ...drain valve If equipped remove microswitches and mounting hardware from valve prior to removal Using a suitable wrench remove the drain valve from the frypot Use Loctite PST567 sealant when installin...

Page 33: ...shooting guides are included in Section 1 9 to assist in identifying some of the more common problems 1 8 1 Ignition Failure Ignition failure occurs when the ignition module fails to sense a flame wit...

Page 34: ...t or pilot system it is most likely in the gas valve Before replacing the gas valve refer to the troubleshooting guides in this chapter 1 8 2 Improper Burner Function In these instances the burner ign...

Page 35: ...opping is an insufficient air supply or drafts that are blowing the pilot flame away from the burner Check for negative pressure conditions in the kitchen area If air is flowing into the kitchen area...

Page 36: ...ordance with the procedures in Section 1 4 An obstructed flue which prevents the fryer from properly exhausting may also be the cause Excessively noisy burners may indicate that the burner gas pressur...

Page 37: ...ommon Computer Complaints Most problems concerning computers have to do with programming them There are four common complaints The complaints their causes and corrective actions are as follows 1 Fryer...

Page 38: ...nutes before using again The operator attempted to filter unheated oil Cold oil is thick and will cause the pump motor to work harder and overheat If the motor runs but the pump does not the pump is b...

Page 39: ...4 VAC required to activate the pump relay coil when the handles are moved to the ON position The activated pump relay coil pulls the pump motor switch in supplying power to the pump motor Filter syste...

Page 40: ...eration When the product button is pressed the timing circuitry activates a coil in the basket lift relay to supply power to the motor The microswitch stops the motor at the lift s lower travel limit...

Page 41: ...at switch A Ensure line voltage is present at the switch A Drain microswitch circuit filter equipped units is open A Ensure drain valve is fully closed and microswitch is functioning Replace microswit...

Page 42: ...e E Continuity from terminal block to gas valve electronic operating thermostat wire is not 0 E Inspect wiring for breaks or shorts and repair if necessary A Incoming gas supply pressures are not with...

Page 43: ...this section depict wiring as of the date of manual publication It may not reflect design changes made to the equipment after publication Refer to the wiring diagram affixed to the unit when actually...

Page 44: ...HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1 SERVICE PROCEDURES 1 39 Computer with Constant Pilot...

Page 45: ...HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1 SERVICE PROCEDURES 1 40 CM4 S Wiring...

Page 46: ...HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1 SERVICE PROCEDURES 1 41 Dean Oil Return Wiring...

Page 47: ...HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 1 SERVICE PROCEDURES 1 42 Dean Oil Return Wiring with Solenoid...

Page 48: ...80 2255 143 290 1977 149 300 1729 154 310 1496 160 320 1320 166 330 1170 171 340 1051 177 350 942 182 360 840 188 370 750 193 380 676 199 390 605 204 400 541 Computer Probe Resistance Chart Celsius Fa...

Page 49: ...ICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2 PARTS LIST 2 1 2 1 High Efficiency Decathlon 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 26 11 27 30...

Page 50: ...embly Natural Gas Electronic Ignition without Computer 810 0705 Tube 1 4 x 20 Pilot Gas Supply one piece gasline 810 0703 Tube 1 4 x 171 2 Pilot Gas Supply one piece gasline 5 220 1231 Bracket Manifol...

Page 51: ...Left Right 201 8945 Panel Inner Door Left 23 106 7542 Door Assembly SCFHD50 C C 230 2256 Panel Outer Door 220 2259 Panel Inner Liner 24 810 0180 Handle Door Wireform 25 210 8077 Handle Door Common Cab...

Page 52: ...owool Blanket 5 x 7 5 x 17 5 230 2057 Support Burner 10 807 3552 Gas Valve Natural Gas Electronic Ignition 24 VAC 3 4 in 1 2 out 807 3628 Gas Valve LP Gas Electronic Ignition 24 VAC 807 3294 Gas Valve...

Page 53: ...nit Church s 16 200 1327 Back Panel Lower Single 200 1222 Back Panel Lower Double 200 4238 Back Panel Lower Church s Double 200 1213 Back Panel Upper Single 17 824 1195 Wireway Control Panel 18 See Co...

Page 54: ...upport Assembly 34 200 8835 Burner Mounting Rail 200 2308 Post Door 201 1182 Gusset Side Panel Left 202 1182 Gusset Side Panel Right 200 1611 Base Cabinet 210 9416 Duct Door Access 200 2713 Plate Suct...

Page 55: ...Side unit exterior 221 0012 Side Panel Left Side with Hole unit exterior 222 0012 Side Panel Right Side with Hole unit exterior 201 4237 Panel Inner Left divider located over filter unit 202 4237 Pan...

Page 56: ...asket 6 x 83 4 x 163 4 26 803 0149 Grid Assembly Mesh 810 2235 Grid Assembly Rack 27 823 5859 Basket Hanger Church s with Deflector 823 5801 Basket Hanger Chili s Single System 6 Splash Guard 823 5856...

Page 57: ...ral 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 Propane Orifices 810 2939 0 1999 ft 810 3058 2000 3999 ft...

Page 58: ...ent Computer FPHD265 565 665 for use with Item 7 7 106 5653 Controller x3 FPHD365 565 8 106 7021 Controller x4 FPHD465 9 211 6640 Frame End Left FPHD65 HD63 10 212 6640 Frame End Right FPHD65 HD63 106...

Page 59: ...3 826 2117 Spark Module Domestic and CE Rajah Connector 807 4375 106 7535 Ignition Cable for computer operated fryers 4 807 1311 Pilot Assembly Natural Gas with Electronic Ignition 807 1553 Pilot Ass...

Page 60: ...tron Board 816 0534 Knob Thermatron Controller 210 5236 Face Plate 3 switch Thermatron 807 3580 Switch Rocker Black Thermatron 807 3579 Switch 6 Prong Thermatron 807 3576 Switch Reset Rocker Thermatro...

Page 61: ...systems 19 Interface Boards 106 6669 Constant Pilot 106 6710 Standing Pilot 20 807 0834 Relay 12VDC 15A 1PDT basket lift 21 807 0833 Relay 12VDC 5A 1PDT latching 807 4114 Relay 24VAC Coil Reset 22 80...

Page 62: ...HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2 PARTS LIST 2 14 2 5 3 Oil Drain Manifold Drain Flush and Drain Valve Components...

Page 63: ...le 1 2 810 1434 Hose Assembly 66 with both ends 1 2 NPT 106 1454SP Nozzle Assembly with handle 106 2387 Heater Strip 120V 25W 36 with 2 pin male connector Flush Oil Drain Line 8 813 0686 Bell Reducer...

Page 64: ...HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2 PARTS LIST 2 16 2 6 Oil Return Manifold Components...

Page 65: ...7 Nut 4 40 Keps Hex w Extended Teeth 10 809 0256 Nut Keps 10 32 Hex 11 809 0354 Screw 4 40 x Round Head 12 809 0942 Washer 5 16 Belleville 18 8 13 810 1003 180 3 way Ball Valve 14 816 0220 Insulation...

Page 66: ...d 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 50 NPT BM 813 0093 Nipple 1 2 x 4 00 NPT BM 813 0281 Nipple 1 2 x 5 00...

Page 67: ...HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2 PARTS LIST 2 19 2 7 Oil Return and 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...

Page 68: ...pple TBE 1 2 NPT x 71 4 Black 13 200 1230 Bracket Front Male Manifold 106 0774SP Suction Manifold Assembly 14 810 0697 Disconnect Male Suction Tube 826 1392 O rings for Male Disconnect pack of 5 15 81...

Page 69: ...9 ITEM PART DESCRIPTION 106 5144SP Filter Pan Assembly includes Items 1 8 1 823 4841 Filter Pan 2 823 5639 Lid Filter Pan 3 823 3573 Ring Hold Down 4 823 5191 Crumb Basket 5 200 8003 Screen Sana Grid...

Page 70: ...RT COMPONENT 106 7543 Filter Pan Assembly includes Items 1 8 1 823 6001 Filter Pan 2 106 4725 Lid Assembly 3 823 6018 Crumb Basket 4 823 3361 Hold Down Ring 5 200 5726 Screen Bottom Filter 6 810 2805...

Page 71: ...tion Components FPHD65 Series Fryers 2 3 4 1 5 6 ITEM PART COMPONENT 106 5081 Filter Pan Assembly includes Items 1 3 6 1 823 5258 Filter Pan 2 823 5857 Lid Assembly 3 823 5851 Crumb Basket 4 106 6466...

Page 72: ...HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS CHAPTER 2 PARTS LIST 2 24 2 9 Basket Lift Components...

Page 73: ...958 Back Basket Lift Motor D60 8 824 0959 Cover Basket Lift Motor D60 9 200 1376 Bracket Restraining 10 106 1463 Motor Assembly 200 1693 Plate Motor Mounting 807 0107 Gear Motor 807 2104 Microswitch C...

Page 74: ...lster Assembly Vat Cover 2 823 3384 Trough Holster Assembly 106 1637SP Cover Full vat HD50 3 106 1447SP Cover Full vat HD60 4 106 2585SP Cover Split vat HD60 106 2897SP Cover FPHD65 106 6494 Cover HD5...

Page 75: ...9 Screw 12 x 3 4 Hex Washer Slotted Head 809 0428 Screw 1 4 20 x 1 2 Hex Head 826 1389 Screw 1 4 20 x 3 4 Hex Head pkg of 10 809 0918 Screw 10 24 x 1 2 Slotted Head 809 0845 Screw 10 32 x 3 8 Hex Slot...

Page 76: ...port Louisiana 71135 1000 Shipping Address 8700 Line Avenue Shreveport Louisiana 71106 TEL 1 318 865 1711 FAX Parts 1 318 688 2200 FAX Tech Support 1 318 219 7135 PRINTED IN THE UNITED STATES SERVICE...

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