Henny Penny PFE-592 User Manual
Henny Penny
Pressure Fryer-Electric
Model PFE-590
Model PFE-592
TECHNICAL MANUAL
Model 590/592
TABLE OF CONTENTS
Section Page
Section 1. TROUBLESHOOTING .............................................................................................. 1-1
1-1 Introduction .................................................................................................... 1-1
1-2 Safety .............................................................................................................. 1-1
1-3 Troubleshooting .............................................................................................. 1-2
1-4 Error Codes .................................................................................................... 1-11
Section 2. MAINTENANCE ........................................................................................................ 2-1
2-1 Introduction .................................................................................................... 2-1
2-2 Maintenance Hints .......................................................................................... 2-1
2-3 Preventive Maintenance ................................................................................. 2-1
2-4 High Temperature Limit Control .................................................................... 2-2
2-5 Fuse Holders ................................................................................................... 2-4
2-6 Power/Pump Switch ....................................................................................... 2-5
2-7 Temperature Probe Replacement .................................................................... 2-6
2-8 Complete Control Panel - Henny Penny ........................................................ 2-7
2-9 Pressure Regulation ........................................................................................ 2-7
2-10 Tilting the Lid Upright ................................................................................... 2-8
2-11 Reversing the Lid Gasket ............................................................................... 2-8
2-12 Lid Counterweight Cables .............................................................................. 2-9
2-13 Pressure Pad ................................................................................................... 2-10
2-14 Lid Adjustment ............................................................................................... 2-11
2-15 Solenoid Valve ................................................................................................ 2-12
2-16 Deadweight Valve ........................................................................................... 2-14
2-17 Removal & Cleaning of Safety Relief Valve .................................................. 2-15
2-18 Pressure Gauge ............................................................................................... 2-16
2-19 Contactors ....................................................................................................... 2-17
2-20 Heating Elements ........................................................................................... 2-19
2-21 Drain Microswitch .......................................................................................... 2-22
2-22 Drain Valve and Extension ............................................................................. 2-23
2-23 Nylatron Strips Replacement ......................................................................... 2-24
Wiring Diagrams ................................................................................................................. 2-26
Section 3. PARTS INFORMATION ............................................................................................. 3-1
3-1 Introduction .................................................................................................... 3-1
3-2 Genuine Parts ................................................................................................. 3-1
3-3 When Ordering Parts ...................................................................................... 3-1
3-4 Prices .............................................................................................................. 3-1
3-5 Delivery .......................................................................................................... 3-1
3-6 Warranty ......................................................................................................... 3-1
3-7 Recommended Spare Parts for Distributors ................................................... 3-1
3-8 Idex of Parts Lists Illustrations ....................................................................... 3-2
106 FM06-028 i
Revised 1-26-10
Model 590/592
Model 590/592
SECTION 1. TROUBLESHOOTING
1-1. INTRODUCTION This section provides troubleshooting information in the form
of an easy to read table.
If a problem occurs during the f rst operation of a new fryer,
recheck the installation per the Installation Section of this
manual.
Before troubleshooting, always recheck the operation pro cedures per Section 3 of this manual.
1-2. SAFETY
Where information is of particular importance or safety related,
the words DANGER, WARNING, CAUTION, and NOTICE
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 infor
mation.
CAUTION used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided,
may result in property damage.
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
W ARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
DANGER INDICATES AN IMMINENTLY
HAZARDOUS SITUATION WHICH, IF NOT
AVOIDED, WILL RESULT IN DEATH OR SERI
OUS INJURY.
1103 1-1
Model 590/592
1-3. TROUBLESHOOTING To isolate a malfunction, proceed as follows:
1. Clearly def ne 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 the problem is solved.
4. Refer to the maintenance procedures in the Maintenance
Section to safely and properly make the checkout and re-
pair needed.
If maintenance procedures are not followed correctly,
injuries and/or property damage could result.
1-2 1103
Model 590/592
Problem Cause Correction
COOKING SECTION
Product color not correct:
A. Too dark
in the program mode; see
Programming Section in
Operator’s Manual
• Temperature too high • Check temperature setting
ture probe
in advance actual frying period
B. Too light
ture probe
pushed. amount of product to be cooked
• Faulty temperature probe • Remove and replace tempera-
• Shortening too old • Change shortening
• Shortening too dark • Filter shortening
• Change shortening
• Breading product too far • Bread product closer to
• Temperature too low • Check temperature setting
• Remove and replace tempera-
• Fryer incorrect preheat • Allow proper preheat time
• Slow fryer heat-up/recovery • Faulty heating element
• Wrong cook button • Be sure to select the correct
C. Product
greasy
when product was dropped
in frypot
temperature probe
frypot immediately after frypot immediately after
depressurization depressurization
1203 1-3
• Shortening old • Replace shortening
• Temperature too low • Check temperature setting
• Temperature not recovered
• Faulty temperature probe • Remove and replace defective
• Frypot overloaded • Reduce cooking load
• Product not removed from • Remove product from
Model 590/592
Problem Cause Correction
COOKING SECTION (Continued)
D. Spotted product • Improper separation of the • Load product into racks
product properly
the product
breading
on product frequently
pressure cooking
E. Dryness of
product cooking
temperature
check for pressure leaks
correct amount of
product to be cooked
Product f avor
(taste):
A. Salty taste
• Breading not uniform on • Sift breading regularly
• Separate product during
• Burned breading particles • Filter the shortening more
• Product sticking together • Separate product prior to
• Moisture loss prior to • Use fresh products
• Overcooking the product • Reduce cooking time
• Reduce cooking
• Low operating pressure • Check pressure gauge reading,
• Wrong cook button pushed • Be sure to select the
• Breading mixture is too salty • Sift breading after each use
• Incorrect breading mixture
• Discard old breading
breading the desired product
B. Burned taste
C. Bland taste
for product (spice content desired product
too low)
• Incorrect choice of • Use breading designed for
• Burned shortening favor • Replace shortening
• Frypot not properly cleaned • Drain and clean frypot
• Raw product not fresh • Use fresh raw product
• Breading mixture incorrect • Use breading designed for
• Cooking temperature too • Check temperature
high (spice f avors lost)
1-4 1103
Model 590/592
Problem Cause Correction
COOKING SECTION (Continued)
D. Rancid taste • Shortening too old • Replace shortening, and
follow recommended care
and use of shortening
follow recommended care
and use of shortening
cooked within the same
shortening. and follow recommended care
and use of shortening
General:
A. Meat separation
from bone procedures
B. Bone color
not proper (black bone)
product (black bone) procedure for product
• Infrequent f ltering • Replace shortening and
• Non-compatible products • Replace shortening
• Use compatible products,
• Raw product not fresh • Use fresh product
• Incorrect meat cut • Use correct meat cutting
• Overcooking • Check cooking time
• Product not fresh • Use fresh product
• Using frozen product • Use fresh product
• Improper processing of • Use proper processing
cooked (red bone)
C. Breading falls
off procedures procedure
product, before breading
D. Product
sticking prior to cooking frying instructions
together
procedure loading procedures
product to be cooked
1103 1-5
• Product not thoroughly • Check cooking time
• Check cooking temperature
• Incorrect breading • Use correct breading
• Product partially frozen • Thoroughly thaw the
• Product breaded too long • Refer to breading and
• Improper loading • Properly load product per
• Wrong cook button pushed • Select correct amount of
Model 590/592
Problem Cause Correction
POWER SECTION
With switch in • Open circuit • Check to see that unit is
POWER position, plugged in
the fryer is com-
pletely inoperative at supply box
(NO POWER)
receptacle
switch; replace if defective
• Check 15 amp fuses
• Check the breaker or fuse
• Check voltage at wall
• Check MAIN POWER
• Check cord and plug
PRESSURE SECTION
Pressure will not
exhaust at end of valve to exhaust tank fryer to cool to release
cook cycle clogged pressure from frypot;
clean all pressure lines,
exhaust stacks, and exhaust
tank
valve per maintenance
section on solenoid valve
Operating
pressure too high fryer to cool to release
pressure from frypot;
remove dead weight and
clean
• Exhaust line from solenoid • Turn unit off and allow
• Solenoid valve clogged • Check and clean solenoid
• Deadweight clogged • Turn unit off and allow
• Exhaust line to stack clogged • Clean exhaust line to stack
DO NOT OPERATE UNIT IF HIGH PRESSURE CONDITIONS EXIST; SEVERE INJURIES
AND BURNS WILL RESULT. PLACE THE POWER/PUMP SWITCH IN THE OFF POSI TION IMMEDIATELY. RELEASE THE PRESSURE BY ALLOWING UNIT TO COOL. THE
PRESSURE WILL THEN DROP. DO NOT RESUME USE OF UNIT UNTIL CAUSE OF HIGH
PRESSURE HAS BEEN FOUND AND CORRECTED.
1-6 1103
Problem Cause Correction
Model 590/592
PRESSURE SECTION (Continued)
Pressure does not • Not enough product in fryer • Place proper quantity of
build or product not fresh fresh product within
frypot to generate steam
removed from dead weight See Unpacking Section of
Operator ’s Manual
• Metal shipping spacer not • Remove shipping spacer.
not closing valve per maintenance
section on the solenoid valve
deadweight valve
adjusted; see Reversing the Lid
Gasket and Lid Adjustment
Sections
maintenance section on the safety
relief valve
• Pressure pad broken or crushed • Replace pressure pads
• Lid open or not latched • Close and latch lid
• Solenoid valve leaking or • Check or clean solenoid
• Dead weight valve leaking • Repair per maintenance section on
• Pressure not programmed • Check programming
• Lid gasket leaking • Reverse gasket or lid needs
• Safety relief valve leaking • Check and replace if necessary per
1103 1-7
Model 590/592
Problem Cause Correction
HEATING OF SHORTENING SECTION
Shortening will not heat
• Blown fuse or tripped • Reset breaker or replace fuse
circuit breaker at supply
box or control panel
• Blown fuse in PC board • Replace glass fuse in board
• Faulty POWER/PUMP switch. • Check POWER/PUMP switch
per maintenance section on
the POWER/PUMP switch
• Faulty cord and plug • Check cord and plug
• Check power at receptacle
• Faulty drain switch • Check drain switch per
maintenance section on
drain switches
• Faulty PC Board • Remove and replace control
panel
• Faulty high limit control switch • Check high limit control
switch per maintenance
section on the high limit
• Drain valve open • Close drain valve
• Possible faulty temperature probe • Replace temperature probe
• Faulty contactor • Check contactor per maintenance
section on contactors
1-8 1002
Model 590/592
Problem Cause Correction
HEATING OF SHORTENING SECTION (Continued)
Heating of shortening • Low or improper voltage • Use a meter and check the
too slow receptacle against data plate
• Weak or burnt out element(s) • Check heating element(s) per
Heating Elements Section
• Points in contactor bad • Check contactor per Heating
Contactors Section
• Wire(s) loose • Tighten
• Burnt or charred wire • Replace wire and clean
connection connectors
Shortening • Programming wrong • Check temperature setting
overheating in the program mode
• Faulty PC board • Remove and replace control
panel
• Faulty temperature probe • Remove and replace temperature
probe
• Check contactor for not • Check faulty contactor per
opening Heating Contactors Section
1103 1-9
Model 590/592
Problem Cause Correction
SHORTENING FOAMING/DRAINING SECTION
Foaming or boiling • Water in shortening • At end of a Cook Cycle,
over of shortening drain shortening and clean
frypot; add fresh shortening
• Condensation line stopped • Remove and clean condensation
up line
• Improper or bad • Use recommended
shortening shortening
• Improper f ltering • Refer to the procedure
covering f ltering the shortening
• Cold zone full of cracklings • Filter shortening
• Improper rinsing after • Clean and neutralize the
cleaning the fryer frypot; rinse with vinegar
to remove the alkaline, then
rinse with hot water and
dry frypot
Shortening will • Drain valve clogged with • Open valve - push cleaning
not drain from frypot crumbs rod through drain opening from
inside of frypot
Shortening leaking • Obstruction in drain • Remove obstruction
through drain valve
• Faulty drain valve • Replace drain valve
1-10 1103
Model 590/592
1-4. ERROR CODES In the event of a control system failure, the digital display
shows an error message. These messages are coded: “E04”,
“E05”, “E06”, “E41”. A constant tone is heard when an error
code is displayed, and to silence this tone, press any of the
product buttons.
DISPLAY CAUSE PANEL BOARD CORRECTION
“E04” Control board overheating Turn switch to OFF position, then turn
switch back to ON; if display still shows
“E04”, the board is getting too hot; check
for signs of overheating behind the control
panel; once panel cools down the controls
should return to normal; if “E04” persists,
replace the control
“E05” Shortening overheating Turn switch to OFF position, then back to
ON; if display shows “E05”, the heating
circuits and temperature probe should be
checked; once the unit cools down, the
controls should return to normal; if “E05”
persists, replace the controls
“E06” Temperature probe failure Turn switch to OFF position, then back to
ON; if the display shows “E06”, the tem-
perature probe should be checked; once the
temperature probe is repaired, or replaced,
controls should return to normal; if “E06”
persists, replace the controls
“E41” Programming Failure Turn switch to OFF position, then back to
ON. If display shows “E41”, the control
should be re-initialized (see programming
section); if the error code persists, replace
the control panel.
“E71” Pump motor relay failure or Replace relay if contacts are stuck closed;
wiring problem check wiring on POWER/PUMP switch, or
wall receptacle; L1 and N may be reversed
1103 1-11
Model 590/592
1-4. ERROR CODES (Continued)
CE Only - Along with the error codes from page 1-11, CE
units have the following self-diagnostic error codes:
DISPLAY CAUSE PANEL BOARD CORRECTION
“E10” High limit Reset the high limit by manually pushing up on the red
reset button; if the high limit does not reset, the high limit
must be replaced per the High Limt Temperature Control
Section
“E15” Drain Switch Close the drain, using the drain valve handle; if display
still shows “E-15”, check the drain microswitch per the
Drain Switch Section
1-12 1103
SECTION 2. MAINTENANCE
Model 590/592
2-1. INTRODUCTION
2-2. MAINTENANCE HINTS
This section provides checkout and replacement procedures,
for various parts of the fryer. Before replacing any parts, refer
to the Troubleshooting Section to aid you in f nding the cause
of the malfunction.
1. A multimeter will help you to check electric components.
2. When the manual refers to the circuit being closed, the
multimeter should read zero unless otherwise noted.
3. When the manual refers to circuit being open, multimeter
should read inf nity.
Do not move fryer with hot shortening in the frypot or
fi lter pan. Severe burns can result from splashing hot
shortening.
4. Remove weights from frame to easily access rear of fryer.
2-3. PREVENTIVE
MAINTENANCE
To ensure a long life of fryers and their components, regular
maintenance should be performed. Refer to the chart below.
Procedure Frequency
Filtering of shortening See KFC’s Standards Library
Changing of shortening See KFC’s Standards Library
Changing the f lter envelope See KFC’s Standards Library
Cleaning deadweight assy. Daily-See Deadweight Valve
Section
Cleaning the frypot See KFC’s Standards Library
Reversing lid gasket Each 90 Days-see Reversing
Lid Gasket Section
Lubricate rear lid rollers Annually-See Lubricating Lid
Rollers Section
Cleaning safety relief valve Annually-See Removal/Cleaning
of Safety Relief Valve Section
307 2-1
Model 590/592
2-4. HIGH TEMPERATURE
LIMIT CONTROL
This high temperature control is a safety, manual reset control,
which senses the temperature of the shortening. If the shortening temperature exceeds 425°F (218°C), this switch opens
and shuts off the heat to the frypot. When the temperature of
the shortening drops to a safe operation limit, manually reset
by pressing the red reset button. The red reset button is located
under the control panel, in the front of the fryer, to the right of
the drain. Once reset, the frypot starts heating.
Checkout
Before replacing a high temperature limit control, check to see
that its circuit is closed.
The shortening temperature must be below 380°F (193°C)
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.
3. Remove the inner heat shield.
4. Remove two nuts securing the high limit bracket to unit,
and pull the bracket from the unit.
5. Remove two screws securing the high limit to the bracket,
and remove the high limit from the bracket.
6. Remove the two electrical wires from the high temperature
limit control.
7. Manually reset control, then check for continuity between
the two terminals after resetting the control. If circuit is
open, replace control, then continue with this procedure. (If
the circuit is closed, high limit is not defective. Reconnect
the two electrical wires.)
2-2 1103
Model 590/592
2-4. HIGH TEMPERATURE
LIMIT CONTROL
(Continued)
To avoid electrical shock of property damage, move the
power switch to OFF and disconnect main circuit
breaker, or unplug cord at wall receptacle.
Replacement
1. If the tube is broken or cracked, the control will open,
shutting off electrical power. The control cannot be reset.
2. Drain shortening from the frypot and discard. A substance
in the tube could contaminate the shortening.
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, and
remove defective control from control panel area.
8. Insert new control and replace screws.
9. Uncoil capillary line, starting at capillary tube, and insert
through frypot wall.
To avoid electrical shock or other injury, run capillary
line under and away from all electrical power wires and
terminals. The tube must never be in such a position
where it could accidentally touch the electrical power
terminals.
10. Carefully bend the capillary tube as shown in photo and
place into bulb brackets.
1103 2-3
Model 590/592
2-4. HIGH TEMPERATURE
LIMIT CONTROL
(Continued)
2-5. FUSE HOLDERS
11. Pull excess capillary line from pot and tighten nut into
frypot wall.
Be sure capillary bulb of high limit is positioned so it does
not interfere with carrier or get damaged when cleaning
frypot.
12. With excess capillary line pulled out, tighten smaller nut.
13. Replace inner and front panels.
14. Ref ll with shortening.
There are two fuse holders on each model of the electric fryers.
To check or change fuse, unscrew black fuse holder cap.
To avoid electrical shock or property damage, move the
power switch to OFF and disconnect main circuit
breaker, or unplug cord at wall receptacle.
Checking Procedure for Fuse Holders
CONTROL PANEL FUSES 3 Phase
Remove the control panel and pull the wires from the fuse
holder terminals. Using a multimeter or continuity light, check
across the terminals. The circuit should be closed. If not, replace the fuse (HP# EF02-007) or fuse holder (HP# EF02-006).
2-4 1103
Model 590/592
2-6. POWER/PUMP SWITCH
The POWER/PUMP switch is a three way rocker switch with a
center OFF position. With switch in the POWER position, the
fryer operates. With switch in PUMP position, the f lter pump
operates, but the unit will not heat.
To avoid electrical shock or property damage, move the
power switch to OFF and disconnect main circuit
breaker, or unplug cord at wall receptacle.
Checkout
1. Remove control panel.
2. Label and remove wires from the switch.
3. OFF position-should be open circuit anywhere on switch.
4. Power position. Check from: #5 to #6 closed circuit
#l to #2 closed circuit
5. Pump position. Check from: #4 to #5 closed circuit
#3 to #2 closed circuit
Check across the jumpers on the wires of POWER/PUMP
switch. These jumpers have resistors and capacitors which
may be faulty.
Replacement
1. With control panel removed, and wires off of the switch,
push in on tabs on the switch to remove from the panel.
2. Replace with new switch, and reconnect wires to switch
following the wiring diagram.
3. Replace the control panel.
1103 2-5
Model 590/592
2-7. TEMPERATURE PROBE
REPLACEMENT
The temperature probe relays actual shortening temperature to
the control. If it becomes disabled, “E06” will show in the display. Also, if temperature is out of calibration more than 10°F,
or 10°C, the temperature probe should be replaced. An Ohm
check can be performed also. See chart at end of this section.
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 control panel.
4. Using a 1/2” wrench, remove the nut on compression f tting.
Figure 2-1
Figure 2-2
5. Remove the temperature probe from the frypot.
6. Place nut and new ferrule on new temperature probe and
insert temperature probe into compression f tting until it
extends one-half (1/2) inch (1.3 cm) into frypot. Use temp-
erature probe gauge provided in temperature probe kit, to
ensure proper placement in frypot. See Figures 2-1 & 2-2.
7. Tighten hand tight and then a half turn with wrench.
Excess force will damage temperature probe.
8. Connect new temperature probe to PC board and replace
control panel.
9. Replace shortening.
10. Turn power on and check out fryer.
2-6 407
Model 590/592
2-8. COMPLETE CONTROL
PANEL-HENNY PENNY
2-9. PRESSURE REGULATION
Should the control panel become inoperative, follow these
instructions for replacing the board.
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 two screws securing he control panel and lift
panel up and out
3. Unplug the connectors going to the control board.
4. Install a new control panel.
The Henny Penny Fryer uses pressure as one of the components of the cooking process. Once the lid is sealed to the
frypot, and the solenoid valve closes, a deadweight valve maintains the correct pressure in the frypot.
The lid has minimal and limited maintenance and repair procedures, which are addressed in the following sections.
The following is a routine maintenance schedule for the Lid:
Every 90 days
• Clean and reverse the lid gasket
Yearly Inspection
• Check Lid Gasket for splits and tears-replace if necessary
• Check Pressure Pads for wear-rotate if necessary
• Check Cam Slide Guides-replace if worn or broken
• Check Lid Rollers-replace if cracked or damaged
1103 2-7
Model 590/592
2-10. TILTING THE LID
UPRIGHT
2-11. REVERSING THE LID
GASKET
The Lid Assembly is easily tilted up for cleaning or servicing.
1. Raise the lid and remove racks and carrier.
2. Grasping the lid handle, lift the front of the lid up until it
stops in an upright position.
Be sure the metal arm on the left side of the lid is in the
vertical position holding lid upright, or severe injuries
could result. (See photo at left).
The gray rubber gasket surrounding the inside of the lid is designed to be reversed.
Because of heat expansion and the pressure used for cooking
process, gasket is constantly under extreme stress. Reversing
the lid gasket will help to assure that the fryer will not lose
pressure through leakage.
1. Put the lid in the upright position, as previously described.
2. Using a thin blade screwdriver, pry out the gasket at the
corners. Remove the gasket.
Check the gasket for any tears or nicks. If the gasket is
damaged it needs to be replaced.
Be sure the metal arm on the left side of the lid is in the
vertical position holding lid upright, or severe injuries
could result. (See photo in Tilting Lid Upright section)
3. Clean the gasket and gasket seat with hot water.
4. Rotate the gasket with the opposite side facing out.
Install the 4 corners of the lid gasket. Smooth gasket into
place, working from the corners towards the middle of each
side.
2-8 1103
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