Henny Penny HHC-980 Service Manual

Henny Penny

Humidified Holding Cabinets

Model HHC-980 Model HHC-983

TECHNICAL MANUAL

Model HHC-980/983

LIMITED WARRANTY FOR HENNY PENNY EQUIPMENT

Subject to the following conditions, Henny Penny Corporation makes the following limited warranties to the original

purchaser only for Henny Penny appliances and replacement parts:

NEW EQUIPMENT: Any part of a new appliance, except baskets, lamps, and fuses, which proves to be defective in material or workmanship within two (2) years from date of original installation, will be repaired or replaced without charge F .O.B. factory , Eaton, Ohio, or F .O.B. authorized distributor . Baskets will be repaired or replaced for ninety (90) days from date of original installation. Lamps and fuses are not covered under this Limited W arranty . T o validate this warranty, the registration card for the appliance must be mailed to Henny Penny within ten (10) days after installation.

FILTER SYSTEM: Failure of any parts within a fryer filter system caused by the use of the non-OEM filters or other unapproved filters is not covered under this Limited Warranty.

REPLACEMENT PARTS: Any appliance replacement part, except lamps and fuses, which proves to be defective in material or workmanship within ninety (90) days from date of original installation will be repaired or replaced without charge F .O.B. factory , Eaton, Ohio, or F .O.B. authorized distributor .

The warranty for new equipment covers the repair or replacement of the defective part and includes labor charges and

maximum mileage charges of 200 miles round trip for a period of one (1) year from the date of original installation.

The warranty for replacement parts covers only the repair or replacement of the defective part and does not include any labor charges for the removal and installation of any parts, travel, or other expenses incidental to the repair or replacement of a part.

EXTENDED FRYPOT WARRANTY: Henny Penny will replace any frypot that fails due to manufacturing or workmanship issues for a period of up to seven (7) years from date of manufacture. This warranty shall not cover any frypot that fails due to any misuse or abuse, such as heating of the frypot without shortening.

0 TO 3 YEARS: During this time, any frypot that fails due to manufacturing or workmanship issues will be replaced at no charge for parts, labor, or freight. Henny Penny will either install a new frypot at no cost or provide a new or reconditioned replacement fryer at no cost.

3 TO 7 YEARS: During this time, any frypot that fails due to manufacturing or workmanship issues will be replaced at no charge for the frypot only . Any freight charges and labor costs to install the new frypot as well as the cost of any other parts replaced, such as insulation, thermal sensors, high limits, fittings, and hardware, will be the responsibility of the owner.

Any claim must be presented to either Henny Penny or the distributor from whom the appliance was purchased. No allowance will be granted for repairs made by anyone else without Henny Penny’s written consent. If damage occurs during shipping, notify the sender at once so that a claim may be filed.

THE ABOVE LIMITED WARRANTY SETS FOR TH THE SOLE REMEDY AGAINST HENNY PENNY FOR ANY BREACH OF W ARRANTY OR OTHER TERM. BUYER AGREES THA T NO OTHER REMEDY (INCLUDING CLAIMS FOR ANY INCIDENT AL OR CONSEQUENTIAL DAMAGES) SHALL BE AV AILABLE.

The above limited warranty does not apply (a) to damage resulting from accident, alteration, misuse, or abuse; (b) if the equipment’s serial number is removed or defaced; or (c) for lamps and fuses. THE ABOVE LIMITED WARRANTY IS EXPRESSL Y IN LIEU OF ALL OTHER W ARRANTIES, EXPRESS OR IMPLIED, INCLUDING MERCHANT ABILITY AND FITNESS, AND ALL OTHER WARRANTIES ARE EXCLUDED. HENNY PENNY NEITHER ASSUMES NOR AUTHORIZES ANY PERSON TO ASSUME FOR IT ANY OTHER OBLIGA TION OR LIABILITY.

Revised 01/01/07

FM06-002

Revised 07-30-07

Model HHC-980/983

TABLE OF CONTENTS

Section Page

Section 1. TROUBLESHOOTING

1-1. Introduction ................................................................................................................. 1-1

1-1. Safety .......................................................................................................................... 1-1

1-3. Troubleshooting .......................................................................................................... 1-1

1-4. Error Codes and Warnings .......................................................................................... 1-5

1-5. Info Mode.................................................................................................................... 1-8

Section 2. LEVEL 2 PROGRAMMING

2-1. Introduction ................................................................................................................. 2-1

2-2. Tech Mode................................................................................................................... 2-1

2-3. Stats Mode................................................................................................................... 2-5

2-4. Data Logging and Manufacturing Mode..................................................................... 2-8

Section 3. MAINTENANCE

3-1. Introduction ................................................................................................................. 3-1

3-2. Maintenance Hints ...................................................................................................... 3-1

3-3. Humidity Sensor Calibration and Replacement.......................................................... 3-1

3-4. Fuse and Fuse Holder Assembly ................................................................................. 3-4

3-5. Power Switch Replacement ........................................................................................ 3-5

3-6. Air T emperature Probe Replacement.......................................................................... 3-6

3-7. Transformer Replacement........................................................................................... 3-8

3-8. Relay Replacement ..................................................................................................... 3-9

3-9. Module T op Removal.................................................................................................. 3-10

3-10. Cooling Fan Replacement ........................................................................................... 3-11

3-11. High Limit - Air Heater Replacement ......................................................................... 3-11

3-12. Blower Motor Replacement ........................................................................................ 3-12

3-13. Air Heater Replacement.............................................................................................. 3-13

3-14. Speaker Replacement .................................................................................................. 3-13

3-15. Complete Panel or PC Board Replacement ................................................................ 3-14

3-16. Float Switch Replacement .......................................................................................... 3-15

3-17. High Limit - Water Heater Replacement..................................................................... 3-16

3-18. Water Heater Replacement.......................................................................................... 3-17

3-19. Drain Valve Replacement............................................................................................ 3-18

3-20. Cleaning Water Strainer .............................................................................................. 3-19

3-21. Water Valve (Solenoid) Replacement ......................................................................... 3-19

3-22. Door Gasket Replacement .......................................................................................... 3-21

Wiring Diagrams......................................................................................................... 3-22

Section 4. PARTS INFORMATION

4-1. Introduction ................................................................................................................. 4-1

4-2. Genuine Parts .............................................................................................................. 4-1

4-3. When Ordering Parts................................................................................................... 4-1

4-4. Prices ........................................................................................................................... 4-1

4-5. Delivery....................................................................................................................... 4-1

4-6. W arranty...................................................................................................................... 4-1

4-7. Recommended Spare Parts for Distributors ............................................................... 4-1

Parts List ..................................................................................................................... 4-2

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SECTION 1. TROUBLESHOOTING

Model HHC-980/983

1-1. INTRODUCTION

This section provides troubleshooting information in the form of an easy to read table.

If a problem occurs during the first operation of a cabinet, recheck the installation per the Installation Section of the Operator’s Manual

Before troubleshooting, always recheck the operation procedures in the Operator’s manual.

1-2. SAFETY Where information is of particular importance or is safety

related, the words NOTICE, CAUTION, or WARNING are used. Their usage is described below.

SAFETY ALERT SYMBOL is used with DANGER, WARNING, or CAUTION which indicates a personal injury type hazard.

NOTICE is used to highlight especially important information.

1-3. TROUBLESHOOTING

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

CAUTION used with the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

To isolate a malfunction, proceed as follows:

1. Clearly define the problem or symptom and when it occurs.

2. Locate the problem in the troubleshooting table.

3. Review all possible causes. Then, one at a time work through the list of corrections until problem is solved.

If maintenance procedures are not followed correctly, injuries and/or property damage could result.

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Model HHC-980/983

1-3. TROUBLESHOOTING (continued)

Problem Cause Correction

OPERATION

A. Product not • Doors left open • Keep doors closed except holding temperature to load and serve product

• Product held too long • Hold product only for recom mended times

• Control temperature set too low • Increase air temperature setpoint to 185o F (85o C); (SP-3) in Special Program Mode

• Bad air heater • Check heaters and replace if bad; see Tech Mode items 10 and 18

• Blower not working • Check blower and replace if bad; see Tech Mode item 18

• Bad air heater or blower relays • Replace relay; see Tech Mode items 10 and 18

• Bad high limit • Check high limit and replace if bad

• Low or improper voltage • Compare receptacle voltage to data plate voltage

• Door Gasket torn or worn • Replace bad door gaskets

• Air probe faulty, open (“E-6A”) • Ohm out the probe and replace

or shorted (“E-6B”) if necessary

B. Cabinet steaming • Humidity setpoint too high • Set humidity to 28% product soggy (SP-4) in Special Program Mode

• Water heater probe faulty, open • Ohm out the probe and replace

(“E-12A”), or closed (“E-12B”) if necessary

• Bad humidity sensor (“E17”) • Replace humidity sensor

• Relay stuck closed • Replace relay

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Model HHC-980/983

1-3. TROUBLESHOOTING (continued)

Problem Cause Correction

OPERATION (Continued)

C. Product dry • Bad float switch (E-18) • Replace float switch

• Bad water heater high limit • Replace high limit

• Bad water heater • Check heater and replace if bad; see Tech Mode item 18

• Humidity setpoint too low • Increase Humidity Setpoint

(SP-4) in Special Program Mode

• No water in pan • Check water shut-off valve

• Clean water valve and replace if necessary

• Replace auto water relay

HEATING SYSTEM

A. Unit not heating • Bad control board • Replace control board

• Bad high limit • Check high limit; replace if bad

• Bad air heater or blower relays • Replace relay

• Bad air heater • Check heaters and replace if bad; see Tech Mode item 18

• Faulty wiring • Check for loose connections or broken wires

• Blown fuse • Change 15 amp fuse

B. Unit not reaching set • Blower not working • Check blower and replace if bad temperature See Tech Mode item 18

• Bad air heater • Check heaters and replace if bad See Tech Mode item 18

• Bad air heater, or blower relays • Replace relay

• Doors left open • Keep doors closed except to load and serve product

• Door gasket torn or worn • Replace bad door gaskets

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Model HHC-980/983

1-3. TROUBLESHOOTING (continued)

Problem Cause Correction

HEATING SYSTEM (Continued)

C. Unit Overheating • Blower not working • Check blower and replace if bad; (“E-5”) see Tech Mode item 18.

• Bad control board • Replace control board

• Relay stuck closed • Replace relay

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Model HHC-980/983

1-4. ERROR CODES AND The display shows the following error codes and warnings WARNINGS when a fault is detected, along with an alarm sound. Both the

heat and humidity systems shut down, except when specified otherwise.

Display Cause Panel Board Correction

“E-4 CPU TOO HOT” • Control board too hot;

unit overheating or louvers clogged

“E-5 AIR TEMP TOO HOT” • Faulty relay, PC board,

or air probe

“E-54A CPU TEMP SENSOR • Faulty PC board

OPEN”

• Turn switch to OFF position, then back to ON; if display still shows “E-4”, the PC board is getting too hot; clean louvers and check cooling fan; replace cooling fan if necessary; once panel cools down, the controls should return to normal; if “E-4” persists, have the PC board replaced.

• Turn switch to OFF position, then back to ON; if display shows “E-5”, check the heating circuits and temperature probe; once the unit cools down, the controls should return to normal; if “E-5” persists, replace the PC board

• Turn switch to OFF position, then back to ON; if display shows “E-54A”, the control should be re-initialized (see Programming Section); if the error code persists, have PC board replaced.

“E-54B CPU TEMP SENSOR • Faulty PC board

SHORTED”

• Turn switch to OFF position, then back to ON; if display shows “E-54B”, the control should be re-initialized (see Programming Section); if the error code persists, have PC board replaced.

“E-6 A AIR TEMP SENSOR • Faulty air probe

F AILED OPEN”

• Turn switch to OFF position, then back to ON; if the display shows “E-6”, the temperature probe should be checked; once the temperature probe is repaired, or replaced, the controls should return to normal; if “E-6” persists, have the PC board replaced

A humidity error only shuts down the humidity system. If a humidity error occurs, and you want to use the cabinet without humidity, turn the humidity off by following the directions for SP-4, Humidity Setpoint, in Special Programming Section of this manual. Once the setpoint is off, the alarm stops, but the error code shows in display. (Includes “E-12A”, “E-12B”, “E17” and “E-18”).

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1-4. ERROR CODES AND WARNINGS (Continued)

Display Cause Panel Board Correction

“E-6B AIR TEMP SENSOR • Faulty air temperature

FAILED SHORTED” probe

Model HHC-980/983

“E-12A WATER HEATER • Faulty water

SENSOR FAILED heater probe OPEN”

“E-12B WATER HEATER • Faulty water

SENSOR FAILED heater probe CLOSED”

“E-17 HUMIDITY SENSOR • Faulty humidity sensor

FAILED”

• Turn switch to OFF position, then back to ON; if the display shows “E-12A”, the water heater should be checked and repaired or replaced (the water heater probe is built into the water heater); the controls should return to normal; if “E-12A” persists, have PC board replaced

• Turn switch to OFF position, then back to ON; if the display shows “E-12B”, the water heater should be checked and repaired or replaced (the water heater probe is built into the water heater); the controls should return to normal; if “E-12B” persists, have PC board replaced

• Turn switch to OFF position, then back to ON; if the display shows “E-17”, the humidity sensor should be checked; once the humidity sensor is repaired, or replaced, the controls should return to normal; if “E-17” persists, have PC board

replaced

“E-18 NO WATER, FLOAT • Float switch stuck or

SWITCH FAILED” faulty; faulty relay

(stuck on);water pan needs cleaned; loose or faulty water heater sensor; acorn nuts on water heater cover loose, or water heater insulation missing or damaged

A humidity error only shuts down the humidity system. If a humidity error occurs, and you want to use the cabinet without humidity , turn the humidity off by following the directions for SP-4, Humidity Setpoint, in Special Programming Section of this manual. Once the setpoint is off, the alarm stops, but the error code shows in display . (Includes “E-12A”, “E-12B”, “E-17” and “E-18”).

1-6 804

• Turn switch to OFF position, then back to ON; if the display shows “E-18”, check and clean float switch; clean water pan; have relay and water heater sensor checked and replace if necessary; tighten acorn nuts on water heater cover; make sure 2 complete pieces of insulation are under the water heater cover; if “E-18” persists, have PC board replaced

Model HHC-980/983

1-3. ERROR CODES AND WARNINGS (Continued)

Display Cause Panel Board Correction

“E-46 DATA SAVE FAILED” • Memory scrambled • Follow directions for SP-9, System

Initialization, in Special Programming

Section of this manual; if “E-46” still persists, replace PC board.

“PLEASE DE-LIME • Water pan needs • Follow the weekly cleaning procedures WATER PAN” cleaned in the Cleaning Procedures Section of

the Operator’s Manual; this warning will not shut down the heat or humidity

“WA TER LEVEL LOW, • Float switch stuck • Check float switch and replace if PLEASE ADD WATER” or faulty; relay faulty necessary; check relay and replace if

(stuck on); water pan necessary; follow weekly cleaning needs cleaned; loose procedures in Cleaning Procedures or faulty water heater Section of Operator’s Manual; check sensor wires at water heater and replace water

heater if necessary (sensor is part of the water heater)

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Model HHC-980/983

1-4. INFO MODE This mode records historic information on the holding cabinet

and operator performance, which could help in troubleshooting a problem.

Press and at the same time and “*INFO MODE*”

shows on display. Press or to access the steps and press to view the statistics within each step.

Information Mode is intended for technical use, but the Operator can view the following information:

1. Error log - last 10 errors and time they occurred

2. Power up log - time of last 10 power-ups

3. Outputs/Inputs - shows the state of unit’s inputs and outputs

a. OUT S_F_W_A (solenoid, fan, water heater, air

heater, relay order from left to right)

b. AMPS S_F_W_A_

c. NC/GD S_F_W_A_ (no connect/ground detection on

outputs to relays)

d. All outputs and inputs S_F_W_A_ P_ (power switch

input) F_ (float switch input)

4. CPU temperature

5. Cabinet air temperature

6. Water heater temperature

7. Humidity counts value

10. Humidity value

11. Analog inputs

1-8 902

Model HHC-980/983

1-4. INFO MODE (Continued)

1. E-LOG (error code log)

Press and “1A. (date & time) *NOW* shows in display.

This is the present date and time.

Press and if a error was recorded, “1B. (date, time, and error code information)” shows in display. This is the latest error code that the controls recorded.

Press and the next latest error code information can be seen. Up to 10 error codes (“1B” to “1K”) can be stored in the E-LOG Section.

Press to continue to P-LOG.

2. P-LOG (power-up log)

Press and “2A. (date & time) *NOW* shows in display.

This is the present date and time.

Press and the latest power-up is shown, “2B. (date, time,) PWR-UP”.

Press and the next latest power-up date is shown. Up

to 10 power-ups (2B to 2K) can be stored in the P-LOG section.

Press to continue onto the outputs/inputs.

3. OUTPUTS/INPUTS

This mode displays the status of components and inputs. If the input or output signal is detected, an identifying letter is displayed (see below). If the signal is not detected, “_” is displayed. Press to view the following:

a. “S_F_W_A_” shows in the display . If the output is on,

“*” shows beside the output letter. Ex: “S*”. If the control senses a problem with the output, “*” flashes.

b. “AMPS S_F_W_A_” shows in the display. A

Checkmark (“√” ) beside the letter indicates normal amps . A flashing “X” beside the letter means a problem exists.

c. “NC/GD S_F_W_A_” shows in the display. This

monitors a possible problem with the relays on the output PC board. A Checkmark (“√ ” ) beside the letter indicates means everything on the output PC board is good. A flashing “X” beside the letter means a problem exists.

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1-4. INFO MODE (Continued) 3. OUTPUTS/INPUTS (Continued)

d. “S_F_W_A_ P_ F_” shows in the display. If the output

or input signal is detected, “*” shows beside the letter. Ex: “S*”. If the control senses a problem with the output, “*” flashes.

Press to continue onto CPU TMP.

4. CPU TMP

This step shows the present PC board temperature.

Press to continue onto cabinet air temperature.

5. CABINET AIR TMP

This step shows the present air temperature inside the cabinet.

Press to continue onto water heater temperature.

6. WATER HEATER TMP

This step shows the present water heater temperature.

Model HHC-980/983

Press to continue to humidity counts value.

7. HUMIDITY COUNTS VALUE

Factory use only!

Press to continue onto the humidity value.

8. HUMIDITY VALUE

This step shows the present humidity level inside the cabinet.

Press to continue onto the analog inputs.

9. ANALOG INPUTS

This step displays the present status of any channel of the controller’s a to d converter. This feature may be useful to a technician troubleshooting a problem with the controller.

The displayed value can be toggled between Volts and Bits by pressing . If the displayed value has a decimal point, it is

voltage (0 to 5 VDC). If no decimal point is shown, the value is a-to-d bits (0 - 4095).

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SECTION 2. LEVEL 2 PROGRAMMING

Model HHC-980/983

2-1. INTRODUCTION

2-2. TECH MODE

The Tech Mode and Stats Mode in the Level 2 Programming Section, have information that could help in troubleshooting a problem with the unit.

Press and hold until “L-2 LEVEL 2”, followed by, “SP PROG”, shows in display.

Press 3 times and “TECH”, followed by, “ENTER CODE” shows in display .

Enter code, to access the following items:

T-1 Software T-2 Cabinet version T-3 Push button test T-4 All on display test T-5 Segments test T-6 Digits test T-7 Decimal points test T-8 LED’ s test

T-9 Air temperature - circuit calibration T-10 Air temperature - user calibration/offset/highest value T-11 W ater heater temperature - circuit calibration T-12 W ater heater temperature - user calibration/of fset/highest

value T-13 Humidity - circuit calibration T-14 Humidity sensor - calibration/offset; specific value sent

with each humidity sensor T-15 Humidity- user calibration/offset/highest value T-16 CPU° - Control temperature - highest value T -17 V iew ADC channel T-18 Outputs/inputs; on outputs steps use the following

hidden buttons [1-5] to toggle on the outputs;

[2] - solenoid valve, [3] - circulation fan, [4] - water

heater, [5] - air heater. T-19 Total init – initialization of programming areas and

statistics.

moves you forward through the above selections and moves you backwards through the selections.

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Model HHC-980/983

2-2. TECH MODE (Continued)

T-1: Software

This section shows “PN/ID/SRL” Press . Henny Penny eprom part number is displayed.

Press . Customer ID (i.e. Pizza Hut) is displayed

Press . Software revision is displayed.

T-2: Cabinet Version

Shows the model number, e.i. HHC-983

T3: Push Button Test

Press any button on the control and a digital display feedback confirms the button is working

T4: All On Display Test

Press any of the product buttons and every LED on the 16 digit display lights

T5: Segments Test

Repeatedly pressing any product button lights one segments in every one of the 16 digit displays

T6: Digits Test

Repeatedly pressing any product button lights all segments in one of the 16 digital displays (scrolls though all 16)

T7: Decimal Point Test

Repeatedly pressing any product button lights a decimal point (DP) in one of the 16 digital displays (scrolls though all 16)

T8: LED Test

Repeatedly pressing any product button lights individual LEDs (scrolls though all LEDs)

T9: Air Temperature - Circuit Calibration

Factory use only

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Model HHC-980/983

2-2. TECH MODE (Continued)

T10: Air Temperature - Calibration/Offset/Highest

A user calibration to make sure the display shows the actual air temperature Press and hold and use to set the display to

match the actual temperature. (+/-15o F)

Press and hold to change the amount of the offset.(+/-15

Press and hold to view the highest air temperature recorded.

Press to reset highest temperature.

T11: Water Heater Temperature - Circuit Calibration

Factory use only

T12: Water Heater Temperature - Calibration/Offset/ Highest

A user calibration to make sure the display shows the actual water heater temperature

Press and hold and use to set the display to

match the actual temperature. (+/-15o F)

Press and hold to change the amount of the offset.(+/-15

Press and hold to view the highest air temperature recorded.

Press to reset highest temperature.

T13: Humidity - Circuit Calibration

See Humidity Sensor Calibration and Replacement Section

T14: Humidity Sensor - Calibration/Offset

A specific value that is sent with the humidity sensor, when necessary; otherwise, this value should be 0

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Model HHC-980/983

2-2. TECH MODE (Continued) T15: Humidity - Calibration/Offset/Highest

A user calibration to make sure the display shows the actual humidity inside the cabinet

Press and hold and use to set the display to

match the actual temperature. (+/-15o F)

Press and hold to change the amount of the offset.

Press and hold to view the highest air temperature recorded.

Press to reset highest temperature.

(+/-15o F)

T16: CPUo - Control Temperature - Highest Value

Shows the highest temperature the control board was exposed to

T17: View ADC Channel

Factory use only

T18: Outputs/Inputs

The following components can be tested:

toggles the solenoid off and on.

toggles the cooling fan off and on.

toggles the water heater off and on.

toggles the air heaters off and on.

T19: Total Initialization

Completely resets any accumulated information and changed settings in the controls; contact Henny Penny Corp. before completing this step!

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