Frymaster Dean Super Runner Series Leitfaden

Dean, a member of the Commercial Food Equipment Service Association, recommends using

CFESA Certified Technicians.

www.frymaster.com

24-Hour Service Hotline

1-800-551-8633

Email: fryservice@welbilt.com

01/2019

*8195948*

Frymaster Dean Millivolt Gas

Fryers

Service & Parts Manual

ESG35T, Super Runner and Super Marathon

Series

NON-CE

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 Dean Factory Authorized Servicer (FAS) 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 the appropriate national and local codes of

the country and/or region in which the appliance is installed.

NOTICE

Drawings and photos used in this manual are intended to illustrate operational, cleaning and

technical procedures and may not conform to onsite management operational procedures.

NOTICE

IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART FOR THIS FRYMASTER

FOOD SERVICE EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART

PURCHASED DIRECTLY FROM FRYMASTER DEAN, OR ANY OF ITS AUTHORIZED SERVICE

CENTERS, AND/OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL

CONFIGURATION, THIS WARRANTY WILL BE VOID. FURTHER, FRYMASTER DEAN AND ITS

AFFILIATES WILL NOT BE LIABLE FOR ANY CLAIMS, DAMAGES OR EXPENSES INCURRED BY

THE CUSTOMER WHICH ARISE DIRECTLY OR INDIRECTLY, IN WHOLE OR IN PART, DUE TO

THE INSTALLATION OF ANY MODIFIED PART AND/OR PART RECEIVED FROM AN

UNAUTHORIZED SERVICE CENTER.

DANGER

Improper installation, adjustment, maintenance or service, and unauthorized alterations or

modifications can cause property damage, injury, or death. Read the installation, operating and

service instructions thoroughly before installing or servicing this equipment. Only qualified

service personnel may convert this appliance to use a gas other than that for which it was

originally configured.

DANGER

Adequate means must be provided to limit the movement of this appliance without depending

upon the gas line connection. Single fryers equipped with legs must be stabilized by installing

anchor straps. All fryers equipped with casters must be stabilized by installing restraining

chains. If a flexible gas line is used, an additional restraining cable must be connected at all

times when the fryer is in use.

iii

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

company or gas supplier.

DANGER

The crumb tray in fryers equipped with a filter system must be emptied into a fireproof container

at the end of frying operations each day. Some food particles can spontaneously combust if left

soaking in certain shortening material. Additional information can be obtained in the filtration

manual included with the system.

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 Dean Service Hotline at 1-800-551-8633.

WARNING

Do not bang fry baskets or other utensils on the fryer’s joiner strip. The strip is present to seal

the joint between the frypot. Banging fry baskets on the strip to dislodge shortening will distort

the strip, adversely affecting its fit. It is designed for a tight fit and should only be removed for

cleaning.

IMPORTANT

Safe and satisfactory operation of Frymaster Dean equipment depends upon its proper

installation. Installation MUST conform with local codes, or in the absence of local codes, to

European Community (CE) Standards.

Frymaster 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 Check Burner Manifold Pressure 1-3

1.5 Adjusting the Pilot Flame 1-5

1.6 Replacing Fryer Components 1-5

1.6.1 Replacing the Operating Thermostat 1-6

1.6.2 Replacing the High-Limit Thermostat 1-7

1.6.3 Replacing the Gas Valve 1-7

1.6.4 Replacing the Frypot 1-7

1.7 Troubleshooting and Problem Isolation 1-8

1.7.1 Pilot Failures 1-10

1.7.2 Improper Burner Functioning 1-11

1.7.3 Improper Temperature Control 1-11

1.7.4 Filtration Problems 1-12

1.7.5 Leaking 1-14

1.8 Wiring Diagrams 1-14

1.8.1 Current Production Units with Honeywell Gas Valve (Non-CE) 1-14

1.8.2 Current Production Units with Honeywell Gas Valve (CE) 1-15

1.8.3 Current Production Units with Robertshaw Gas Valve (After May, 2002) 1-16

1.8.4 UFF Filtration Wiring Diagram 1-17

Frymaster 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, ESG35T, SM35G, SM40G and SM50G Systems 2-10

2.4.3 SM60G and SM80G Systems 2-13

2.5 Oil Drain Manifold, Drain Flush and Drain Valve Components 2-16

2.6 Oil Return Manifold Components 2-20

2.7 Oil Return and Oil Flush Components 2-23

2.8 Under Fryer Filter (UFF) Components 2-27

2.8.1 SM50 and SM60 Series Fryers (Except IHOP) 2-27

2.8.2 SM50 Series Fryers, IHOP UFF 50 with Filter Leaf 2-28

2.8.3 SM80 Series Fryers 2-29

2.9 Single Under Fryer Filter (SUFF) Components 2-30

2.9.1 SM50 Series Fryers 2-30

2.9.2 SM60 and SM80 Series Fryers 2-31

FRYMASTER DEAN MILLIVOLT GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1-1

1.1 Functional Description

Frymaster Dean ESG, 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). Frymaster 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 to five, according to the fryer model and size.

Flames originate from orifices in a burner manifold positioned beneath cast-iron burners. The burners

are positioned in the tube openings, at the front of the frypot. Diffusers within each tube distribute the

flame evenly throughout the tube. The diameter of the orifices differs for natural (CE:G20/G25) and LP

(CE:G31) gas as indicated in the accompanying table.

NON-CE

(

Altitudes of 2000 feet or less

)

MODEL INPUT

(BTU) GAS

TYPE ORIFICE

MM (INCH) ORIFICE

PART NO. QTY EQUIPMENT

PRESSURE

MBAR INCH W.C.

SM20GM 50

NAT

LP 2.18(#44)

1.40

(

#54

)

8102050

8102324 2

210

27.5 4

ESG35T 70

67 NAT

LP 2.18 (#44)

1.40

(

#54

)

8104389

8103529 3

39.5

30 3.8

SM 35 (40) GM

SR 42GM 105 NAT

LP 2.80(#35)

1.70(#51) 8102040/*8103097

8102064/*8103099 3

3 10

27.5 4

SR 52 GM

SM 50 GM 120 NAT

LP 2.53(#39)

1.51(#53) 8102048

8102059 4

4 10

27.5 4

SR 62 GM

SM 60 GM

SR 62 GM

(Australia)

150

NAT

2.53(#39)

1.51(#53)

2.53(#39)

1.61(#52)

8102048

8102059

8102048

810

2063

27.5

3.6

9.6

SM 80 GM 165 NAT

LP 2.58(#38)

1.61(#52) 8102062

8102063 5

5 10

27.5 4

CE ONLY

(

Altitudes of 2000 feet or less

)

MODEL INPUT

(kW) GAS

TYPE ORIFICE

MM (INCH) ORIFICE

PART NO. QTY/

COLOR

EQUIPMENT

PRESSURE

MBAR INCH W.C.

SM20GM 15 G20

G25

G31

2,40

1,51

8102060

8102059

2/BLUE

2/RED

10,0

15,0

27,0

4,0

6,0

10,8

SM 35 (40) GM

SR 42GM 26 G20

G25

G31

2,40

8102060/*8103101

8102059

*8103102

3/BLUE

3/RED

10,0

15,0

4,0

6,0

SR 52 GM

SM 50 GM 30 G20

G25

G31

2,40

1,51

8102060

8102059

4/BLUE

4/RED

10,0

15,0

27,0

4,0

6,0

10,8

SR 62 GM

SM 60 GM 37,5 G20

G25

G31

2,40

1,51

8102060

8102059

5/BLUE

5/RED

10,0

15,0

27,0

4,0

6,0

10,8

SM 80 GM 37,5 G20

G25

G31

2,40

1,51

8102060

8102059

5/BLUE

5/RED

10,0

15,0

27,0

4,0

6,0

10,8

*SR42 units built after 4/07.

1-2

1.1 Functional Description (cont.)

An electromechanical millivolt gas valve regulates gas flow to the burner manifold. Frymaster Dean

millivolt fryers use a pilot ignition system to control burner firing.

Operating

Thermostat

Thermopile

Pilot

High-Limit

Main Valve Magnet

Pilot Magnet

Gas Valve

Pilot Ignition System

The pilot ignition system is made up of the pilot orifice, pilot hood, and a thermopile or

thermocouple. The pilot serves two purposes: lighting the burner and heating the thermopile/

thermocouple. In operation, the thermopile/thermocouple is in contact with the pilot flame and

generates millivolts. The millivolt output passes through a normally closed high-limit switch and

energizes the gas valve pilot coil, which in turn opens the pilot valve. If the pilot flame is

extinguished, voltage is lost to the gas valve pilot coil and the pilot valve closes.

Thermostats

Frymaster Dean millivolt fryers are equipped with adjustable operating thermostats. The

temperature at which the thermostat opens and closes is adjusted by turning a knob.

Frymaster Dean millivolt fryers are also equipped with a high-limit thermostat.In the event that the

fryer fails to properly control the oil temperature, the high-limit thermostat prevents the fryer from

overheating to the flash point. The high-limit thermostat acts as a normally closed power switch that

opens when exposed to temperatures above 410ºF (210°C) for CE fryers and 435-450ºF (224-232°C)

for non-CE fryers. Once opened, the high limit must be manually reset before operating the fryer.

Functional diagram of a typical millivolt system.

1-3

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 shortening can cause severe burns. Avoid contact. Under all circumstances, oil

must be removed from the fryer before attempting to move it to avoid oil spills, and

the falls and severe burns that could occur. This fryer may tip and cause personal

injury if not secured in a stationary position.

4. Relocate the fryer for service accessibility. If fryer is equipped with legs, lift the fryer to relocate

it. Damage to the leg or leg support channel can result if the fryer is not lifted when moving.

5. After servicing is complete, reconnect the unit to the gas supply and reattach the restraining

devices.

6. Refill the frypot with cooking oil.

1.3 Cleaning the Gas Valve Vent Tube

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 ordinary binding 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 that the opening is pointing downward.

1-4

1.4 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).

3. Insert the fitting for a gas pressure-measuring device into the pressure tap hole.

4. Place the gas valve in the "Pilot" position (non-CE), or press white button and light pilot (CE).

After the pilot is lit (turn non-CE gas valve to "ON" position), set thermostat knob to 350°F

(177°C). When the burner lights and continues to burn, note gas pressure reading for correct

pressure in accordance with the table on page 1-1.

5. To adjust burner gas pressure, remove the cap from the gas valve regulator and adjust to correct

pressure.

6. Place the fryer power switch and the gas valve in the "OFF" position. Remove the pressure-

measuring device fitting from the pressure tap hole and reinstall the pressure tap plug.

7. Repeat step 4 to continue fryer operation.

Pressure tap locations on CE gas valves (left) and non-CE gas valves (right).

1-5

1.5 Adjusting the Pilot Flame

1. Remove the cover shown in the illustration below to access the pilot flame adjustment screw in

the gas valve.

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 pilot flame-adjustment cover.

4. Five-tube millivolt fryers: Adjust the trailing pilot (adjustment valve located on the burner

manifold) until a 1-½ inch (38 mm) flame is obtained.

1.6 Replacing Fryer Components

1.6.1 Replacing the Operating Thermostat

1. Drain the fryer and turn the gas off.

2. Remove the thermostat knob by pulling straight out on the knob with a firm, steady pull.

3. Disconnect the wires from the thermostat.

4. Remove the two mounting screws to release the thermostat control from its mounting bracket.

5. Remove the screws and clamp that secure the thermostat bulb to the frypot. Remove spring from

bulb and reinstall on replacement thermostat bulb.

Pilot adjustment locations on CE gas valves (left) and non-CE gas valves (right).

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