Henny Penny 500, 600 Installation Manual
Model 500/561/600
SECTION 2. MAINTENANCE
2-1. INTRODUCTION
2-2. MAINTENANCE
HINTS
This section provides procedures for the checkout and
replacement of the various parts used within the fryer.
Before replacing any parts, refer to Section 1, Troubleshooting.
It will aid you in determining the cause of the malfunction.
1. You may use two test instruments to check the electric
components.
• A continuity light
• An ohmmeter
2. When the manual refers to the circuit being closed,
the continuity light will be illuminated or the
ohmmeter should read zero unless otherwise noted.
3. When the manual refers to the circuit being open,
the continuity light will not illuminate or the
ohmmeter will read 1 (one).
A continuity tester cannot be used to check coils or motors.
103 2-1
Model 500/561/600
2-3. PREVENTIVE
MAINTENANCE
SCHEDULE
2-4. REMOVING THE
CONTROL PANEL
To ensure a long life of the fryers and their components, regular
maintenance should be performed. Refer to the chart below.
Frequency Action
Daily (3-4 loads) Filter shortening
Daily Clean deadweight valve cap,
weight, and orifi ce
30 Days Lubricate spindle threads and ball seat
90 Days Reverse lid gasket
90 Days Check limit stop adjustment
90 Days Check and tighten element spreader bars
Once a year Remove and clean safety relief valve
To replace parts inside the fryer you will often need to remove
the control panel. The following steps provide the correct
procedure:
Removal
1. Place the main power switch to the OFF position.
(This switch is labeled POWER/OFF/PUMP.)
Step 3
Step 4
To avoid electrical shock or property damage, move the
power switch to OFF and disconnect main circuit
breaker, or unplug cord at wall receptacle.
2. Remove the two screws from the bottom of the
control panel.
3. Carefully slide the control panel upward until it lifts off
the metal hangers.
4. With the fryer door closed, place the lower edge of the
control panel in the slot between the door and the frame
of the fryer.
Installation
1. To install the control panel, hook it on the metal hangers
that hold the top of the panel in place.
2. Install the two screws in the bottom of the panel.
3. Reconnect power to the fryer.
2-2 103
Model 500/561/600
2-5. TEMPERATURE
REGULATION
(SINGLE STAGE)
Description
The cooking temperature is controlled by the front panel
thermostat and monitored by its sensing bulb mounted
just inside the frypot. Various thermostats are available,
but all work on the same principle.
1202 2-3
Model 500/561/600
2-5. TEMPERATURE
REGULATION
(SINGLE STAGE)
(Continued)
Internal Operation
Drain Microswitch
High Limit Temperature Control
The thermostat bulb is connected to the thermostat by a thin
capillary tube. When the temperature rises, the fl uid inside the
bulb expands (as in a thermometer) and pushes fl uid through the
tube into the control panel thermostat. When the frypot temperature is lower than the thermostat setting, the TEMP light is illuminated and frypot is being heated. When the temperature setting
is reached, a switch inside the thermostat opens the circuit to the
heat source and turns off the TEMP light. When the frypot starts
to cool, the switch closes the circuit to the heat source.
This interlock provides protection for the frypot in the event an
operator inadvertently drains the shortening with the switch in the
power position. The heat will automatically shut off when the
drain valve is opened.
The high limit temperature provides the safety feature of interrupting the heat if the temperature ever exceeds the safe operating
limits. On electric models it must be manually reset when the
frypot cools. Refer to High Temperature Limit Control section for
maintenance of the high limit temperature control.
2-4 103
Model 500/561/600
2-6. CALIBRATING
THE STANDARD
SINGLE STAGE
THERMOSTAT
Henny Penny does not recommend that a fi eld calibration be
performed on the thermostats mentioned above. The reasons for
this are as follows:
• The thermostat is calibrated in a controlled environment from
the factory. The thermostat manufacturers do not recommend
any adjustments to the thermostat in the fi eld, as this will affect
the factory calibration.
• The difference between a hand-held thermometer and an
installed thermostat can be quite large due to shortening
temperature variation.
• The adjustment of a thermostat is not precise, since the dial
reads only in 25 degrees F increments. The accuracy of a
thermostat needs to be less than 5 degrees F.
If a thermostat is not reading accurately and suspected to be
faulty, Henny Penny suggests that the thermostat be replaced.
If you have any questions, please do not hesitate to call the
Technical Services Department.
2-7. TESTING THE
THERMOSTAT
Procedure
If the thermostat fails to work properly, perform the following
checks before replacing the thermostat:
1. Remove electrical power supplied to the fryer.
To avoid electrical shock or property damage, move the
power switch to OFF and disconnect main circuit
breaker, or unplug cord at wall receptacle.
2. Remove the control panel.
3. With an ohmmeter or continuity light, check for continuity
as follows.
4. On a standard (single temperature) thermostat, check
between terminals 52 and 53. Move the temperature knob
from OFF to maximum.
• At OFF, the circuit should be open.
• At maximum, the circuit should be closed.
504 2-5
Model 500/561/600
2-8. THERMOSTAT
REPLACEMENT
(ALL MODELS)
ELECTRIC
GAS
1. Remove electrical power supplied to the fryer.
To avoid electrical shock or property damage, move the
power switch to OFF and disconnect main circuit
breaker, or unplug cord at wall receptacle.
2. Drain the shortening from the frypot.
3. Remove the thermostat sensing bulb from the bulb
holder inside the frypot.
4. Place your thumb at the bend in the capillary tube,
where it comes into the frypot, and straighten the
bulb. The bulb should be extending out into the
frypot.
Step 3
5. Remove the two screws which secure the control panel
to the frame of the fryer.
6. Lift the panel up and off the metal fl anges.
2-6 1202
Model 500/561/600
2-8. THERMOSTAT
REPLACEMENT
(ALL MODELS)
(Continued)
LARGE SCREW
NUT
SMALL SCREW
NUT
7. With the door of the fryer closed, put the bottom edge
of the control panel in the slot between the door and
the frame of the fryer.
8. Locate the thermostat on the back of the panel.
9. Remove the thermostat knob on the front of the control
panel.
10. Remove the two screws which secure the thermostat to
the back of the panel. Remove the thermostat bezel.
11. Remove the small inside screw nut which holds the
capillary line.
12. Remove the large screw nut.
13. Label the wire connections to the thermostat for correct
identifi cation when the new thermostat is installed.
14. Disconnect the wires.
15. Remove the defective thermostat.
16. Install the new thermostat.
1202 2-7
Model 500/561/600
2-8. THERMOSTAT
REPLACEMENT
(ALL MODELS)
(Continued)
17. Connect the wires to the new thermostat.
Be careful not to cross the wires or thermostat will
not operate properly.
18. Uncoil the capillary tube.
19. Insert the bulb through the wall of the frypot.
To avoid electrical shock or other injury, the capillary
line must run under and away from all electrical power
wires. The tube must never be in contact with the
electrical power wires or terminals.
20. Install the thermostat pot fi tting into the wall of the frypot
and tighten.
21. Replace the thermostat sensing bulb into the mounting
bracket.
Do not bend the capillary tube where it connects
to the sensing bulb, or damage to capillary will
result.
22. ELECTRIC only: slip the bulb holder in place. With
bulb in place, tighten the clamp screw.
23. Pull the excess capillary tube from the inside of the frypot.
24. Insert and tighten the inside screw nut into the thermostat
pot fi tting.
25. Install the two screws on the front of the control panel
which secure the thermostat to the back of the panel.
Install the thermostat bezel.
26. Install the thermostat knob.
2-8 1202
Model 500/561/600
2-8. THERMOSTAT
REPLACEMENT
(ALL MODELS)
(Continued)
2-9. HIGH TEMPERATURE
LIMIT CONTROL
(ELECTRIC AND
GAS MODELS)
Electric
Gas
Red Reset
Button
27. Secure the control panel with the 4 screws.
28. Reconnect power to the fryer.
29. Calibrate the thermostat per paragraph 2-6.
Description
This high temperature control is a manual reset control which
senses the temperature of the shortening. If the shortening
temperature exceeds the safe operating limit, this control switch
will open and shut off the heat to the frypot. When the
temperature of the shortening drops to the safe operating limit,
the control must manually be reset.
To locate the high limit reset button, open the door to the drain
pan. Look up under the controls and to the right of the fi lter
handle for a red reset button. (On the left for single phase units.)
Checkout
Before replacing a high temperature limit control, check to
see that its circuit is closed.
The shortening temperature must be below 380º F to accurately perform this check.
1. Remove electrical power supplied to the fryer.
To avoid electrical shock or property damage, move the
power switch to OFF and disconnect main circuit
breaker, or unplug cord at wall receptacle.
2. Remove the control panel and insert it in the slot above the
door. Refer to paragraph 2-4.
103 2-9
Model 500/561/600
2-9. HIGH TEMPERATURE
LIMIT CONTROL
(ELECTRIC AND
GAS MODELS)
(Continued)
Step 3
Electric
3. Remove the two electrical wires from the high
temperature limit control.
4. Check for continuity between the two terminals after
resetting the control. If the circuit is open, replace the
control, then continue with this procedure. (If the circuit
is closed, the high limit is not defective. Reconnect the
two electrical wires.)
Replacement
To avoid electrical shock or property damage, move the
power switch to OFF and disconnect main circuit
breaker, or unplug cord at wall receptacle.
1. If the capillary tube is broken or cracked, the control will
open,shutting off electrical power. The control cannot be
reset.
2. Drain shortening from the frypot.
High Limit Capillary Tube
Gas
Step 1
3. Remove control panel.
4. Loosen small inside screw nut on capillary tube.
5. Remove capillary bulb from bulb holder inside the frypot.
6. Straighten the capillary tube.
7. Remove larger outside nut that threads into pot wall.
8. Remove the two screws that secure the high limit to
the high limit bracket.
9. Remove defective control from control panel area.
10. Insert new control and replace screws.
11. Uncoil capillary line, starting at capillary tube, and
insert through frypot wall.
To avoid electrical shock or other injury, the capillary
line must run under and away from all electrical power
wires. The tube must never be in contact with the
electrical power wires or terminals.
2-10 1202
Model 500/561/600
2-9. HIGH TEMPERATURE
LIMIT CONTROL
(ELECTRIC AND
GAS MODELS)
(Continued)
Electric
Gas
Step 13
12. Carefully bend the capillary bulb and tube toward bulb holder
on heating elements, and on electric units, toward the welded
clips on gas units.
13. Slip capillary bulb into bulb holder located on heating ele-
ments, on electric units, and snap the bulb in place in the
welded clips, on gas units. Pull excess capillary line from pot
and tighten nut into frypot wall.
Be sure capillary bulb of high limit is located behind
capillary bulb of thermostat. Both capillary bulbs
and bulb holders should be positioned as not to
interfere with basket or when cleaning the frypot
wall, or damage to capillary tube could result.
14. With excess capillary line pulled out, tighten smaller nut.
15. Replace front panel.
16. Refi ll with shortening.
1202 2-11
Model 500/561/600
2-10. HEATING ELEMENTS
(ELECTRIC MODELS)
Description
Each electric fryer uses three heating element assemblies.
Heating elements are available for 208, 220/240, or 440/480
voltage. Check the data plate inside the door to determine the
correct voltage.
Maintenance Hint
If the shortening’s temperature recovery is very slow, or at a
slower rate than required, this may indicate defective heating
element(s). An ohmmeter will quickly indicate if the elements are
shorted or open.
Checkout
1. Remove electrical power supplied to the fryer.
To avoid electrical shock or property damage, move the
power switch to OFF and disconnect main circuit
breaker, or unplug cord at wall receptacle.
2. Remove the control panel and insert it in the slot
above the door. Refer to paragraph 2-4.
3. Perform an ohm check on one heating element at a
time, with wires disconnected from element. If the
resistance is not within tolerance, replace the element.
HEATER RESISTANCE IN
P/N POWER VOLTAGE OHMS (COLD)
18233-1 4500W 208VAC 9+1
18233-2 4500W 230VAC 11+1.5
18233-4 3750W 208VAC 11+1.5
18233-5 3750W 220VAC 12+2
18233-6 3750W 480VAC 60+5
18233-7 4500W 480VAC 50+4
18233-8 4500W 380VAC 32+3.5
2-12 103
Model 500/561/600
2-10. HEATING ELEMENTS
(ELECTRIC MODELS)
(Continued)
Replacement
1. Drain the shortening.
2. Remove the thermostat bulb holder from the heating
element inside the frypot.
3. Remove the heating element wires from the terminals by
removing nuts (5) and washers (6 and 7). Label each
so it can be replaced in the same position on the new
element.
4. Loosen the bolts on the four element spreaders.
5. Slide the element spreaders to the center of the heating
element.
6. Remove the brass nuts (4) and washers (3), which
secure the ends of the elements through the frypot wall.
(Reference Figure 3-16)
7. Remove the heating elements from the frypot as a group
by lifting the far end and sliding them up and out toward
the rear of the frypot.
Always install new rubber O-rings (2) when installing
heating elements.
8. Install new heating elements with new rubber O-rings (2)
mounted on terminal ends, and spreaders loosely
mounted in the center of the stacked elements.
9. Replace the heating elements, terminal end fi rst at
approximately 45º angle, slipping the terminal ends
through the front wall of the frypot.
1202 2-13
Model 500/561/600
2-10. HEATING ELEMENTS
(ELECTRIC MODELS)
(Continued)
10. Replace the brass nuts (4) and washers (3) on the
heating element terminals. Tighten the brass nuts to
30 foot lbs of torque.
11. Move the element spreaders from the center of the
element, into a position which will spread each element
apart evenly on all four sides, and tighten.
12. Replace the thermostat bulb holder on the top element,
and position the bulb between the top and second element
midway from side to side, and tighten screw which holds
the bulb in place.
13. Reconnect the wires to the appropriate terminal as
labeled when they were removed.
14. Replace the front control panel.
15. Connect the power cord to the wall receptacle or close
wall circuit breaker.
Heating elements should never be energized without
shortening in the frypot, or damage to elements could
result.
16. Check the heating elements as described in paragraph 2-17 of
Operator’s Manual.
17. Replace the shortening in the frypot.
2-14 1202
Model 500/561/600
2-11. HEATING
CONTACTORS
(ELECTRIC MODELS)
Description
Each electric fryer requires two switching contactors. One is the
primary contactor and the second in line is the heat contactor.
When open, the primary contactor allows no power to fl ow to the
heat contactor. When closed, the primary contactor completes
the timer circuit and the high limit (heat) circuit. It also supplies
power to the heat contactor which is controlled by the thermostat.
Checkout (power removed)
1. Remove electrical power supplied to the fryer.
To avoid electrical shock or property damage, move the
power switch to OFF and disconnect main circuit
breaker, or unplug cord at wall receptacle.
2. Remove the control panel and insert it in the slot above
the door. Refer to Removing the Control Panel section.
3. Perform a check on the contactor as follows:
Test Points Results
from 23 to 29 open circuit
from 24 to 28 open circuit
from 25 to 27 open circuit
from 30 to 34 open circuit
from 31 to 35 open circuit
from 32 to 36 open circuit
from 22 to 26 ohm reading 415
from 33 to 37 ohm reading 415
103 2-15
Model 500/561/600
2-11. HEATING
CONTACTORS
(ELECTRIC MODELS)
(Continued)
Checkout (power suppled)
To avoid electrical shock, make connections before applying power, take reading, and remove power before removing meter leads. The following checks are performed with
the wall circuit breaker closed and the main power switch
in the ON position.
1. With power re-applied, set the thermostat to its maximum
temperature.
2. On fryers using single phase power, check voltage as
follows:
Test Points Results
from pin D on The voltage
circuit breaker to: should read
terminal 34 the same at
terminal 35 each terminal.
terminal 36 It should
(If voltage is not correspond to
present, check out- the voltage
put of primary rating stated
contactor at on the data
terminals 27, 28, plate.
and 29.)
2-16 1202
Model 500/561/600
2-11. HEATING
CONTACTORS
(ELECTRIC MODELS)
(Continued)
3. On fryers using three-phase power, check voltage
as follows:
Test Points Results
Heat contactor The voltage
from terminal 34 to 35 should read
from terminal 35 to 36 the same at
from terminal 34 to 36 each terminal.
Primary contactor It should
from terminal 27 to 28 correspond to
from terminal 28 to 29 the voltage
from terminal 27 to 29 rating stated
on the data
plate.
Replacement
If either contactor is defective it must be replaced as follows:
To avoid electrical shock or property damage, move the
power switch to OFF and disconnect main circuit
breaker, or unplug cord at wall receptacle.
1. Remove only those wires directly connected to the
contactor being replaced. Label the wires.
2. Remove the two mounting screws on the base plate
and remove contactor.
3. Install the new contactor and tighten the two mounting
screws.
4. Connect the labeled wires to their respective positions.
5. Install the control panel per paragraph 2-4.
6. Reconnect power to the fryer and test the fryer for
proper operation.
1202 2-17
Model 500/561/600
2-12. GAS BURNER
ASSEMBLY
(GAS MODELS)
Description
The gas model fryer has a gas burner assembly consisting of a
burner casting, orifi ces, thermocouple, pilot holder, and main
gas control valve.
Safety Precautions
PILOT
HOLDER
MAIN GAS
CONTROL VALVE
THERMOCOUPLE
ORIFICE
BURNER
CASTING
If converting from natural gas to propane gas or from propane
gas to natural gas, conversion must be done by a qualifi ed
service technician.
TO AVOID PERSONAL INJURY OR PROPERTY
DAMAGE, BEFORE STARTING THIS PROCEDURE,
MOVE THE MAIN POWER SWITCH TO THE OFF
POSITION. DISCONNECT THE MAIN CIRCUIT
BREAKERS AT THE CIRCUIT BREAKER BOX OR
UNPLUG SERVICE CORD FROM WALL RECEPTACLE. TURN OFF THE MAIN GAS SUPPLY TO THE
FRYER AND DISCONNECT AND CAP THE MAIN
SUPPLY LINE TO FRYER, OR POSSIBLE EXPLOSION COULD RESULT.
1. Remove the control panel per paragraph 2-4.
2. Place the control panel back in upright position, in the
metal fl anges.
2-18 103
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