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Dean Millivolt Gas Fryers
Service & Parts Manual
Super Runner and Super Marathon Series
NON-CE &
Dean, a member of the Commercial Food Equipment Service Association, recommends using
CFESA Certified Technicians.
24-Hour Service Hotline
MAY 2008
1-800-551-8633
*8195948*
www.frymaster.com
Email: service@frymaster.com
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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 Dean Factory Authorized Service Center (FASC) or other qualified professional should perform installation, maintenance, and repairs. Installation, maintenance, or repairs by unqualified personnel may void the manufacturer’s warranty. NOTICE This equipment must be installed in accordance with th
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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. 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 followed MUST be posted in a prominent location in the event the operator detects a gas leak. This information can be obtained from the local gas compa
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Dean Millivolt Gas Fryers Service and Parts Manual TABLE OF CONTENTS Page # 1. SERVICE PROCEDURES 1-1 1.1 Functional Description 1-1 1.2 Accessing Fryers for Servicing 1-3 1.3 Cleaning the Gas Valve Vent Tube 1-3 1.4 Calibrating the Operating Thermostat 1-4 1.5 Check Burner Manifold Pressure 1-5 1.6 Adjusting the Pilot Flame 1-6 1.7 Replacing Fryer Components 1-6 1.7.1 Replacing the Operating Thermostat 1-6 1.7.2 Replacing the High-Limit Thermostat 1-8 1.7.3 Replacin
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Dean Millivolt Gas Fryers Service and Parts Manual TABLE OF CONTENTS (CONT.) Page # 2. PARTS LIST 2-1 2.1 Cabinetry Components, Single Fryers 2-1 2.2 Cabinetry Components, Multi-Battery Systems 2-4 2.3 Component Box Components and Related Components (Non-CE and CE) 2-6 2.4 Frypot and Burner System Components 2-8 2.4.1 SM220 and SM20/20/~ Systems 2-8 2.4.2 SR Series, SM35G, SM40G and SM50G Systems 2-10 2.4.3 SM60G and SM80G Systems 2-13 2.5 Oil Drain Mani
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DEAN MILLIVOLT GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1.1 Functional Description Dean Super Runner and Super Marathon Series fryers are millivolt fryers, which require no electricity to operate (systems with built-in filtration and/or other accessories will require electric power). Dean millivolt fryers contain a welded steel frypot (stainless or cold-rolled) that is heated by gas flames diffused evenly through tubes built into the frypot. The number of tubes varies from three
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1.1 Functional Description (cont.) An electromechanical millivolt gas valve regulates gas flow to the burner manifold. Dean millivolt fryers use a pilot ignition system to control burner firing. High-Limit Thermopile Operating Thermostat Gas Valve Pilot Pilot Magnet Main Valve Magnet Functional diagram of a typical millivolt system. Pilot Ignition System The pilot ignition system is made up of the pilot orifice, pilot hood, and a thermopile or thermocouple. The pi
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1.2 Accessing Fryers for Servicing DANGER Moving a fryer filled with cooking oil may cause spilling or splattering of the hot liquid. 1. Drain all cooking oil from the fryer. 2. Shut off the gas supply to the unit and disconnect the unit from the gas supply. 3. Remove any attached restraining devices. DANGER Fryers must be at room temperature, empty of oil, and if fitted with legs, lifted during movement to avoid damage and possible bodily injury. DANGER Hot short
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1.4 Calibrating the Operating Thermostat 1. Ensure the frypot is filled to the proper level with oil before proceeding. 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 oil temperature to become uniform. If using solid shortening, stir to get all shortening in the bottom of the frypot melted. 5. Insert a good-grade thermometer or pyrometer probe into the oil, with the end n
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1.5 Check Burner Manifold Pressure WARNING This task should be performed by qualified service personnel only. 1. Ensure that the gas valve knob is in the "OFF" position (non-CE), or press red button to turn gas valve off (CE). 2. Remove the pressure tap plug from the gas valve (see illustration below). Pressure tap locations on CE gas valves (left) and non-CE gas valves (right). 3. Insert the fitting for a gas pressur
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1.6 Adjusting the Pilot Flame 1. Remove the cover shown in the illustration below to access the pilot flame adjustment screw in the gas valve. Pilot adjustment locations on CE gas valves (left) and non-CE gas valves (right). 2. Using a small, flat-tipped screwdriver, turn the pilot flame adjustment screw counterclockwise to increase the length of the flame or clockwise to decrease the length of the flame. Adjust the flame to a length of 1-½ inches (38 mm). 3. Reinstall the
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1.7.1 Replacing the Operating Thermostat (cont.) 6. First, loosen the capillary tube compression fitting until it slides freely on the capillary tube. Second, loosen the frypot pass-through nut until it slides freely on the capillary tube. Remove the capillary tube and bulb from the frypot. 7. Install the replacement thermostat capillary tube and bulb in the frypot. Apply a small amount of Loctite PST567 compound or equivalent to the threads of the frypot pass-through nut and s
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1.7.2 Replacing the High-Limit Thermostat 1. Follow instructions for replacing operating thermostat, section 1.7.1, omitting steps 2 and 12. 1.7.3 Replacing the Gas Valve DANGER Drain the frypot or remove the handle from the drain valve before proceeding further. 1. Disconnect fryer from the gas supply. 2. Disconnect wiring from the gas valve terminal block, marking each wire to facilitate reconnection. 3. Disconnect the pilot gas line fitting from the gas valve and re
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1.7.4 Replacing the Frypot (cont.) 9. Recover the drain valve, high-limit thermostat, operating thermostat, and burner manifold assembly from the failed frypot. 10. Clean the threads on the recovered parts, apply Loctite PST 567 or equivalent thread sealer, and install them on the replacement frypot. 11. Reverse Steps 1-9 to install the replacement frypot in the cabinet. For SUFF/UFF Filtration-equipped systems, consult the Decathlon Series Gas Fryers Service & Parts Manual (819-
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ROBERTSHAW-UNITROL 7000 SYSTEM CHECK 1. Complete System Check With thermostat contacts closed and gas cock dial in the “ON” position, the main burner TH TH should ignite. Measure the reading between TP the 2 & 3 terminals. If the reading is more than 100MV, replace the gas valve. THTP 1 3 TH 2. System Resistance Check 2 With thermostat contacts closed and main burner “ON”, measure the millivolt reading between the 1 and 3 terminals. The reading should be less than 80MV. If not
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Pilot failures fall into one of two categories – failure to light or failure to remain lit. Pilot Fails to Light 1. Gas is not being supplied to the valve: Check for a closed gas cutoff valve upstream of the gas valve. Also verify that the gas line quick disconnect fitting at the rear of the fryer (if so equipped) is properly connected. 2. Blocked pilot orifice: If gas is reaching the valve but the pilot will not light, check for an obstruction in the pilot orifice, especially in ne
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1.8.2 Improper Burner Functioning Fluctuating flame intensity is normally caused by improper or fluctuating incoming gas pressure, but may also be the result of variations in the kitchen atmosphere. Variation in the kitchen atmosphere is usually caused by air conditioning and/or ventilation units starting and stopping. Changes in airflow patterns can also affect flame intensity. If the incoming gas pressure is correct and stable, check for variations in the kitchen atmosphere. Flames
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1.8.4 Filtration Problems The majority of filtration problems arise from operator error. One of the most common errors is placing the filter paper on the bottom of the filter pan rather than over the filter screen. Whenever the complaint is "the pump is running, but no oil is being filtered", check the installation and size of the filter paper. Verify that the O-ring on the slip-connection is in good condition. A missing or worn O-ring allows the pump to suck air, decreasing its ef
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1.8.4 Filtration Problems (cont.) 3. Prior to reassembly, the inside housing must be clean and free of any sediment or debris. Failure to completely clean the inside housing and ring gear will cause gear binding after reassembly. Incorrectly sized or installed paper will allow food particles and sediment to pass through and clog the suction tube on the bottom of the filter carriage. Particles large enough to block the suction tube may indicate that the crumb tray is not being used.
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ON 1.9 Wiring Diagrams 1.9.1 Current Production Units with Honeywell Gas Valve (Non-CE) HIGH-LIMIT THERMOSTAT 12C SAFTY DRAIN PP TH SWITCH (OPTIONAL) 17C PILOT PP TH GENERATOR IN-LINE SPLICE ON/OFF 1/2 P.S.I. HONEYWELL SWITCH (OPTIONAL) 1C 17C 2C IN-LINE SPLICE FENWALL OPERATING THERMOSTAT OPERATING THERMOSTAT 8050438D White Thermopile Red Combination Gas Valve TH PP Red Red High-Limit Operating Thermostat PP TH Black Black Old Style Honeywell Millivolt Gas Valve Wiring
