Manitowoc Decathlon Series Installation & Operation Manual
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Manitowoc Decathlon Series Installation & Operation Manual

Manitowoc Decathlon Series Installation & Operation Manual

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D, SCFD, CFD, YHBT#14, HBT#50 Models
HD, SCFHD Models
FRYMASTER FPD65, FPHD65, FPLHDC65 Models
Frymaster, a member of the Commercial Food Equipment Service Association, recommends
using CFESA Certified Technicians.
PRINTED IN
THE UNITED STATES
OF AMERICA
24-Hour Service Hotline 1-800-551-8633
NON-CE &
AUG 2014
*8197001*

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  • Page 1 D, SCFD, CFD, YHBT#14, HBT#50 Models HD, SCFHD Models FRYMASTER FPD65, FPHD65, FPLHDC65 Models NON-CE & Frymaster, a member of the Commercial Food Equipment Service Association, recommends using CFESA Certified Technicians. 24-Hour Service Hotline 1-800-551-8633 AUG 2014 *8197001* PRINTED IN THE UNITED STATES OF AMERICA...
  • Page 2 Please read all sections of this manual and retain for future reference. NOTICE This appliance is intended for professional use only and is to be operated by qualified personnel only. A Frymaster Factory Authorized Servicer (FAS) or other qualified professional should perform installation, maintenance, and repairs.
  • Page 3 It is designed for a tight fit and should only be removed for cleaning. NOTICE IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART FOR THIS MANITOWOC FOOD SERVICE EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART PURCHASED DIRECTLY FROM FRYMASTER, OR ANY OF ITS AUTHORIZED SERVICERS, AND/OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL CONFIGURATION, THIS WARRANTY WILL BE VOID.

  • Page 4: Table Of Contents

    High Efficiency Decathlon (HD) Series Gas Fryers Installation & Operation Manual TABLE OF CONTENTS Page # INTRODUCTION Applicability and Validity After Purchase Ordering Parts Service Information Computer Information Safety Information Service Personnel IMPORTANT INFORMATION Receiving and Unpacking Equipment General Product Description Principles of Operation Rating Plate Pre-Installation...
  • Page 5 High Efficiency Decathlon (HD) Series Gas Fryers Installation & Operation Manual TABLE OF CONTENTS (CONT.) Page # FRYER OPERATIONS Initial Start-up Boil-Out Procedure Final Preparation CONTROLLER OPERATING INSTRUCTIONS Operating Instructions: Electronic Thermostat Controller Electronic Thermostat Controller/Computer with Back-Up Thermostat FILTRATION General Filter Preparation Daily Filter Operation...

  • Page 6: Introduction

    CHAPTER 1: INTRODUCTION 1.1 Applicability and Validity The Decathlon Series gas model family (D and HD models) has been approved by the European Union (EU) for sale and installation in the following EU countries: AT, BE, KE, KD, ES, FI, FR, GB, IE, IT, LU, NL, NO, PT and SE.

  • Page 7: Service Information

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 1: INTRODUCTION 1.4 Service Information Call the Frymaster Service Hotline, 1-800-551-8633, for the location of your nearest factory authorized service center. To assist you more efficiently, always provide the service technician with the model number, gas type, serial number, and the nature of the problem.

  • Page 8: Service Personnel

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 1: INTRODUCTION 1.7 Service Personnel A. Qualified and/or Authorized Operating Personnel Qualified/authorized operating personnel are those who have carefully read the information in this manual and have familiarized themselves with the equipment functions, or have had previous experience with the operation of equipment covered in this manual.

  • Page 9: Important Information

    DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2.1 Receiving and Unpacking Equipment A. Check that the container is upright. Use an outward prying motion - no hammering - to remove the carton. Unpack the fryer carefully and remove all accessories from the carton. Do not discard or misplace these, as they will be needed.

  • Page 10: Product Description

    Questions? Call 1-800-551-8633. 2.3 Product Description Decathlon Series gas fryers are energy efficient, tube-style, gas-fired units. All units are shipped completely assembled with accessories packed inside the frypot. All units are adjusted, tested and inspected at the factory before shipment. Sizes, weights and input rates of all models are listed in this manual.

  • Page 11: Rating Plate

    A manual gas shut-off valve must be installed in the gas supply line ahead of the fryers for safety and ease of future service. Decathlon Series gas fryers require 120VAC 60 cycle or 230VAC single-phase 50 Hz (International) electrical service and are equipped with a 16-3 SJT grounded flexible power cord for a direct connection to the power supply.

  • Page 12: Air Supply And Ventilation

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2.6 Pre-installation (cont.) C. Installation Standards 1. U.S. installations must meet: 2. Canadian installations must meet: American National Standard Institute CAN 1-B149 Installation Codes ANSI Z83.11 Canadian Gas Association American Gas Association 55 Scarsdale Road 8501 E.

  • Page 13: Equipment Installed At High Altitudes

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 2: IMPORTANT INFORMATION 2.7 Air Supply and Ventilation (cont.) D. Do not place the fryer’s flue outlet directly into the plenum of the hood, as it will affect the gas combustion of the fryer. E.

  • Page 14: Installation

    DECATHLON (D & HD) 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, and then place the fryer where it is to be installed.

  • Page 15: Installing Casters And Legs

    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. Decathlon Series gas fryers cannot be curb-mounted and must be equipped with either legs or casters provided.

  • Page 16: Gas Connections

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.4 Gas Connections DANGER Before connecting new pipe to this appliance the pipe must be blown out thoroughly to remove all foreign material. Foreign material in the burner and gas controls will cause improper and dangerous operation.
  • Page 17 HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.4 Gas Connections (cont.) Gas Supply Type and Pressure Gas Supply Type Gas Supply Pressure Natural Gas 6-10" W.C. (Dynamic) Propane (LP) Gas 11-13" W.C. (Dynamic) DANGER When pressure-testing incoming gas supply lines, disconnect the fryer from the gas line if the test pressure is ½"...
  • Page 18 HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 3.4 Gas Connections (cont.) DANGER When pressure-testing incoming gas supply lines, disconnect the fryer from the gas line if the test pressure is ½" PSI [3.45 kPa (14 inches W.C.)] or greater to avoid damage to the fryer’s gas piping and gas valve(s).

  • Page 19: Gas Specifications

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 2. The fryer must be restrained by means independent of the flexible coupling or connector in order to limit the movement of the fryer. Restraining brackets are located on the back panel of the fryer for the attachment of restraints. 3.

  • Page 20: Gas Conversion Procedures

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION Gas Specifications CE ONLY (Altitudes of 2000 feet or less) EQUIPMENT INPUT ORIFICE ORIFICE MODEL PRESSURE (kW) TYPE (MM) PART NO. MBAR INCH W.C. 2,40 810-2060 10,0 D20G 15,0 2,40 810-2060 15,0 1,51...

  • Page 21: Electrical Connections

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 3: INSTALLATION 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). DANGER This fryer is equipped with a three-prong (grounding) plug for protection against electrical shock and must be plugged directly into a properly grounded, three-prong...

  • Page 22: Fryer Operations

    DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.1 Initial Start-up WARNING The on-site supervisor is responsible for ensuring that operators are made aware of the inherent hazards of operating a hot oil frying system, particularly the aspects of system operation, oil filtration, draining and cleaning procedures.
  • Page 23 HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.1.1 Pilot Lighting Procedures, Standing Pilot Only Initial Pilot Lighting: All Frymaster fryers are tested, adjusted and calibrated to sea level conditions before leaving the factory. Adjustments to assure proper operation of pilot may be necessary on installation to meet local conditions, low gas pressure, differences in altitude and variations in gas characteristics.

  • Page 24: Boil-Out Procedure

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.1.2 Pilot Lighting Procedures, Electronic Ignition Systems WARNING Never use a match or taper to light pilot on this ignition system. 1. Turn gas "ON". 2. Turn electric power "ON" with the appropriate rocker switch or controller/computer. 3.
  • Page 25 HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.2 Boil-Out Procedure (cont.) A. Pour cleaning solution into the frypot and add water to the bottom OIL LEVEL line scribed in the back of the frypot. B. Operating thermostat-equipped fryers: Set dial/temperature controller to 225°F (107ºC), just above that of boiling water.

  • Page 26: Final Preparation

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.2 Boil-Out Procedure (cont.) Close the drain, add fresh water (without boil-out solution) and wash all surfaces of the frypot. Drain again. K. Refill the frypot with fresh water and vinegar to neutralize any residual boil-out solution. Wash all surfaces of the frypot.
  • Page 27 HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 4: FRYER OPERATIONS 4.3 Final Preparation (cont.) D. Operating Thermostat: 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"...

  • Page 28: Controller Operating Instructions

    CHAPTER 5: CONTROLLER OPERATING INSTRUCTIONS 5.1 Operating Instructions: Electronic Thermostat Controller Decathlon Series gas fryers come standard with an electronic thermostat controller, which incorporates a temperature-control circuit board, a potentiometer, and a temperature probe. The potentiometer knob is turned to the desired temperature setting, similar to a standard thermostat.
  • Page 29 HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 5: CONTROLLER OPERATING INSTRUCTIONS 5.1 Operating Instructions: Electronic Thermostat Controller (cont.) FRYER POWER SWITCH – This switch turns the fryer on and off. When the power switch is in the "ON" position, the indicator light will be lit when calling for heat. BOIL-OUT SWITCH (Optional) –...
  • Page 30 HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 5: CONTROLLER OPERATING INSTRUCTIONS 5.2 Electronic Thermostat Controller/Computer (cont.) MAIN POWER SWITCH – connects/disconnects primary power; double-lighted with center position "OFF". One main switch controls two electronic thermostats/Compu-Fry or remote computers. When the main power switch is in the center position, power is removed from the two fryers controlled by the electronic thermostats/Compu-Fry or remote computers.

  • Page 31: Filtration

    DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 6: FILTRATION 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. 6.1 General Most SUFF/UFF systems use filter paper as the filter medium. Some filter systems can be special ordered with a filter-leaf assembly, which eliminates the need for filter paper.

  • Page 32: Filter Preparation

    DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 6: INSTALLATION AND OPERATION Filter Preparation On initial installation and before each use, clean the filter: a. remove all loose parts from the filter, wash the filter pan and all accessories in hot, soapy water, and dry thoroughly.
  • Page 33 DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 6: INSTALLATION AND OPERATION 6.2.1 Filter Unit Types (cont.) FILTER LEAF A filter leaf is a fine mesh screen which is reusable and takes the place of disposable paper. Oil moves through the leaf, leaving behind impurities. 1.
  • Page 34 DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 6: INSTALLATION AND OPERATION 6.2.2 Assembling the Filter FILTER PAPER AND HOLD DOWN RING 1. Place the support grid in the bottom of filter pan. Support grid properly placed in filter pan. 2.
  • Page 35 DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 6: INSTALLATION AND OPERATION 6.2.2 Assembling the Filter (cont.) 4. Sprinkle 8 ounces (227g) of filter powder on the filter sheet. Ensure the powder covers the filter paper evenly. Sprinkle the proper amount of filter powder evenly over the paper.
  • Page 36 DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 6: INSTALLATION AND OPERATION 6.2.2 Assembling the Filter (cont.) FILTER LEAF 1. Remove the filter pan from the fryer by pulling out on the filter pan handle. 2. Remove the filter pan lid picking it up off of the pan.
  • Page 37 DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 6: INSTALLATION AND OPERATION 6.2.2 Assembling the Filter (cont.) 7. Sprinkle 8 ounces (227g) of filter powder on the filter leaf. Ensure the powder covers the mesh evenly. Applying filter powder to filter-leaf. 8.

  • Page 38: Daily Filter Operation

    DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 6: INSTALLATION AND OPERATION 6.2.3 Installing the Filter 10. Slide the filter inside the fryer cabinet. Ensure the male-female pickup tubes are fully engaged. Ensure the filter pan opening is directly under the center dump tube. The filter pan slides under the fryer (left), connecting with a male connector (right).
  • Page 39 DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 6: INSTALLATION AND OPERATION 6.3.2 Filtering Tools Assemble tools to be used for filtering. These are supplied with the filter starter kit included with the fryer/filter system:  Frypot/Filter Brush - used to clean frypot and filter pan sides and bottom, heating elements, and to dislodge sediment during filtration or oil change.

  • Page 40: Operating The Filter

    DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 6: INSTALLATION AND OPERATION 6.4 Operating the Filter 6.4.1 Pan Preparation and Operation See Section 6.2.1, Assembling the Filter, and Section 6.2.2, Installing the Filter, for the appropriate filter preparation procedure. For optional filter hose and wand, see Section 6.4.3, Optional Filter Hose and Wand Operation.
  • Page 41 DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 6: INSTALLATION AND OPERATION 6.4.1 Pan Preparation and Operation (cont.) 4. After ensuring the filter pan is correctly positioned under the drain tubes, move the red handle to the open position (right) to drain the frypot into the filter pan.
  • Page 42 DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 6: INSTALLATION AND OPERATION 6.4.2 Filter Operation 6. Oil will begin to pump from the filter pan into the frypot. If the frypot tubes, sides and bottom have sediment deposits, clean the frypot with the cleaning brush included with the fryer.
  • Page 43 DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 6: INSTALLATION AND OPERATION 6.4.2 Filter Operation (cont.) 9. After all oil is pumped back into the frypot, bubbles will form, indicating air in the oil return lines. Allow the oil to bubble for 10- 15 seconds to ensure all oil is evacuated from the return lines.
  • Page 44 DECATHLON SERIES GAS FRYERS CHAPTER 5: UNDER FRYER FILTER (SUFF/UFF) FILTRATION 6.4.2 Filter Operation (cont.) 12. Do not allow crumbs to accumulate in the crumb tray. The crumb tray MUST be emptied into a fireproof container at the end of frying operations EACH DAY (see DANGER statement below).
  • Page 45 DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 6: INSTALLATION AND OPERATION 6.4.3 Optional Filter Hose and Wand Operation Some frying systems come equipped with an optional filter hose, wand, and toggle switch to facilitate the removal of debris from the frypot. The hose attaches to a no quick-disconnect on the bottom front of the fryer and is controlled using a toggle switch on the fryer control panel.
  • Page 46 DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 6: INSTALLATION AND OPERATION 6.4.3 Hose and Wand Operation (cont.) 4. The oil will start to flow immediately into the Yellow frypot. Keep the wand inside the frypot at all times while the filter pump is activated. The red handle is attached to the drain valve.

  • Page 47: Preventative Maintenance

    Any equipment works better and lasts longer when maintained properly and kept clean. Cooking equipment is no exception. The Decathlon Series gas 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.

  • Page 48: Periodic/Annual

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 7: PREVENTATIVE MAINTENANCE 7.3 Periodic/ Annual The fryer should be inspected and adjusted periodically by qualified service personnel as part of a regular kitchen maintenance program. Frymaster recommends that the fryer be inspected at least annually by a Factory Authorized Servicer as follows: ...

  • Page 49: Troubleshooting

    DECATHLON (D & HD) SERIES GAS FRYERS CHAPTER 8: TROUBLESHOOTING DANGER Hot shortening will cause severe burns. Never attempt to move this appliance when filled with hot shortening or to transfer hot shortening from one container to another. DANGER This equipment should be unplugged when servicing, except when electrical circuit tests are required.

  • Page 50: Main Burner Malfunctions

    HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 8: TROUBLESHOOTING 8.1 Pilot Burner Malfunction (cont.) C. Pilot flame of proper size, but is unstable. Flame wavers and does not envelope the thermocouple completely at all times.  Check for drafts that might be caused by air conditioning equipment or make-up air apparatus.
  • Page 51 HIGH EFFICIENCY DECATHLON (HD) SERIES GAS FRYERS CHAPTER 8: TROUBLESHOOTING 8.2 Main Burner Malfunctions (cont.) D. Fryer will not reach the temperature setting and/or runs erratically. Incorrect location of sensor probe or defective temperature sensor. Loose wiring/wire connection. E. Fryer shortening temperature cannot be controlled; fryer runs at high-limit temperature. Defective operating thermostat or temperature probe;...
  • Page 52 Frymaster, 8700 Line Avenue, 8700 Line Avenue, Shreveport, Louisiana 71106 TEL 1-318-865-1711 FAX (Parts) 1-318-688-2200 FAX (Tech Support) 1-318-219-7135 SERVICE HOTLINE PRINTED IN THE UNITED STATES 1-800-551-8633 819-7001 AUG 2014...

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