Duke Infrared Heatsink User manual

Service Manual
11/18/2015
INFRARED
HEATSINK™
HOLDING UNIT
Includes Standalone,
Kitchen Minder and
VISOR models
MODELS
IRHS22
IRHS23
IRHS24
IRHS34
IRHS42
This manual is Copyright © 2015 Duke Manufacturing Co. All rights reserved.
Reproduction without written permission is prohibited. Duke is a registered trademark of the Duke Manufacturing Co.
Duke Manufacturing Co.
2305 North Broadway • St. Louis, MO 63102-1405
Phone: [phone] • Toll Free: 1-800-735-3853 • Fax: [phone]
[email protected] • www.dukemfg.com
Please read this manual completely before attempting
to install, operate or service this equipment.
This document is prepared for trained Duke service technicians. It is not to be used by anyone not properly
qualied to perform these procedures.
This Service Manual is not all encompassing. If you have not been trained on servicing this product, be sure
to read the manual completely before attempting servicing. Be sure all necessary tools, test equipment,
and skills are available. Those procedures for which you do not have the proper skills and test equipment
must be performed only by a qualied Duke trained service technician.
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Infrared HeatSink (IRHS) Holding Unit Service Manual
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IMPORTANT WARNING AND SAFETY INFORMATION
READ THIS MANUAL THOROUGHLY BEFORE OPERATING, INSTALLING OR PERFORMING MAINTENANCE
ON THE EQUIPMENT.
READ THIS MANUAL THOROUGHLY BEFORE OPERATING, INSTALLING OR PERFORMING
MAINTENANCE ON THE EQUIPMENT
FAILURE TO FOLLOW INSTRUCTIONS IN THIS MANUAL CAN CAUSE PROPERTY DAMAGE,
INJURY OR DEATH.
DO NOT USE OR STORE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN
THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
DO NOT OPERATE THIS EQUIPMENT WITHOUT PROPERLY PLACING AND SECURING ALL
COVER AND ACCESS PANELS.
IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN
CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATING AND MAINTENANCE
INSTRUCTIONS THOROUGHLY BEFORE INSTALLING THIS EQUIPMENT.
FOR YOUR SAFETY



CAUTION
Observe the following:
• Provideandmaintainadequateminimumclearancesfromallwallsandcombusblematerials.
• Provideandmaintainadequateclearanceforairopenings.
• Keeptheequipmentareafreeandclearofcombusblematerial.
• Operateequipmentonlyonthetypeofelectricityindicatedonthespecicaonplate.
• Retainthismanualforfuturereference.

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TABLE OF CONTENTS
SPECIFICATIONS........................................................................................................................................ 5
IRHS22 .............................................................................................................................................. 5
IRHS23 .............................................................................................................................................. 6
IRHS24 .............................................................................................................................................. 7
IRHS34 .............................................................................................................................................. 8
IRHS42 .............................................................................................................................................. 9
REMOVALANDREPLACEMENTOFPARTS..............................................................................................10
 EQUIPMENTUSEDINTHESEINSTRUCTIONS...................................................................................10
 ELECTRICALLOCKOUT/TAGOUTPROCEDURE...................................................................................10
 ESDWRISTSTRAP............................................................................................................................. 11
 DECKASSEMBLYCOMPONENTS.......................................................................................................12
  MENUBARS..............................................................................................................................12
  KEYPADDISPLAYS....................................................................................................................... 14
  RTD(TEMPERATURE)SENSORS.................................................................................................16
HIGH LIMIT THERMOSTATS........................................................................................................18
HEAT ELEMENTS........................................................................................................................21
  EMITTER(IRBULB)SOCKETS.....................................................................................................24
  EMITTERS(IRBULBS).................................................................................................................27
 CONTROLCOMPARTMENTCOMPONENTS–STANDALONE&KITCHENMINDERMODELS(only)...28
  POWERSWITCH......................................................................................................................... 28
  USBADAPTER............................................................................................................................28
  DAYPARTSWITCH.......................................................................................................................29
  RELAYS(SmartPowerModules)................................................................................................ 29
  CONTROLLER............................................................................................................................. 30
TRANSFORMER..........................................................................................................................30
  RTDBOARD................................................................................................................................31
FUSES AND FUSE HOLDER.........................................................................................................32
 CONTROLCOMPARTMENTCOMPONENTS–KITCHENMINDERMODEL(only)...............................33
  KITCHENMINDERMASTERBOARD(ifinstalled).......................................................................33
  KITCHENMINDERADAPTERBOARD(ifinstalled)......................................................................34
  MOUNTINGPLATE(ifinstalled).................................................................................................35
  COUPLERS(ifinstalled)..............................................................................................................36
 CONTROLCOMPARTMENTCOMPONENTS–VISORMODEL(only).................................................37
  12VPOWERCONTROLBOARD.................................................................................................37
  POWERCONTROLBOARD–ACM..............................................................................................38
  POWERCONTROLBOARD–103M............................................................................................39
  POWERCONTROLBOARD–TRIACDRIVE.................................................................................40
FUSE HOLDER AND FUSES.........................................................................................................41
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TROUBLESHOOTING&DIAGNOSTICS.....................................................................................................42
 IRHSTROUBLESHOOTINGFLOWCHART..........................................................................................42
 IRHSTROUBLESHOOTINGGUIDE.....................................................................................................43
 IRHSCOMPONENTTECHNICALSPECIFICATIONS.............................................................................44
OPERATIONS........................................................................................................................................... 47
 OPERATINGPROCEDURES................................................................................................................ 47
  OPERATIONS.............................................................................................................................. 47
   ChangingDayparts.............................................................................................................. 48
   DisplayLink,HoldTime,orTemperature............................................................................49
  DIAGNOSTICS.............................................................................................................................50
   CheckingHeatSinkTemperature........................................................................................50
   CheckingIRBulbFuncon.................................................................................................. 50
   CheckingProductSengs(viaUSBle).............................................................................50
   ErrorCodes.........................................................................................................................51
   TemperatureCheckProcedure...........................................................................................51
CLEANING&ROUTINEMAINTENANCE..................................................................................................52
 CLEANING........................................................................................................................................52
 RECOMMENDEDSUPPLIES...............................................................................................................52
 DAILYINSPECTIONCHECKLIST.......................................................................................................... 52
 DAILYCLEANINGPROCEDURES........................................................................................................ 53
WEBSITEPROGRAMMING......................................................................................................................54
WIRINGSCHEMATICS.............................................................................................................................58
 IRHSDECKWIRING........................................................................................................................... 58
IRHS22 Wiring DIAGRAM.................................................................................................................59
IRHS23 WIRING DIAGRAM............................................................................................................... 60
IRHS24 WIRING DIAGRAM............................................................................................................... 61
IRHS34 WIRING DIAGRAM............................................................................................................... 62
IRHS42 WIRING DIAGRAM............................................................................................................... 63
 VISORINTERFACECABLEWIRINGDIAGRAM...................................................................................64
 KITCHENMINDERCONNECTIONS....................................................................................................65
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SPECIFICATIONS
IRHS22
Before Serial# 10140480
(10/1/14) As of Serial# 10140480
Shipping Weight 125lbs/56.7kg 110lbs/49.9kg
Model Electrical Plug H W D H W D
IRHS22-208 208V ~ 12 A, 50/60 Hz NEMA6-15P
14.4in/
36.6cm
19.3in/
49.0cm
20.1in/
51.1cm
13.3in/
33.8cm
19.3in/
49.0cm
20.1in/
51.1cm
IRHS22-230 230V ~ 12 A, 50/60 Hz SHUKO,16AMP
(as of 11/3/14)IEC,16AMP
IRHS22-240 240V ~ 12 A, 50/60 Hz NEMA6-15P
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IRHS23
Up to Serial# 101413198
(10/20/14) Aer SN# 101413198
Shipping Weight 160lbs/72.6kg 143lbs/64.9kg
Model Electrical Plug H W D H W D
IRHS23-208 208V ~ 12 A, 50/60 Hz NEMA6-15P
14.4in/
36.6cm
26.4in/
67.1cm
20.1in/
51.1cm
13.3in/
33.8cm
26.4in/
67.1cm
20.1in/
51.1cm
IRHS23-230 230V ~ 12 A, 50/60 Hz SHUKO,16AMP
(as of 11/3/14)IEC,16AMP
IRHS23-240 240V ~ 12 A, 50/60 Hz NEMA6-15P
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IRHS24
Before Serial# 10140545
(10/3/14) As of Serial# 10140545
Shipping Weight 195lbs/88.4kg 181lbs/82.1kg
Model Electrical Plug H W D H W D
IRHS24-208 208V ~ 12 A, 50/60 Hz NEMA6-15P
14.4in/
36.6cm
33.4in/
84.8cm
20.1in/
51.1cm
13.3in/
33.8cm
33.4in/
84.8cm
20.1in/
51.1cm
IRHS24-230 230V ~ 12 A, 50/60 Hz SHUKO,16AMP
(as of 11/3/14)IEC,16AMP
IRHS24-240 240V ~ 12 A, 50/60 Hz NEMA6-15P
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IRHS34
Before Serial# 10140032
(10/1/14) As of Serial# 10140032
Shipping Weight 275lbs/124.7kg 243lbs/110.2kg
Model Electrical Plug H W D H W D
IRHS34-208 208V ~ 16 A, 50/60 Hz NEMA6-20P
20.9in/
53.1cm
33.4in/
84.8cm
20.1in/
51.1cm
19.3in/
49.0cm
33.4in/
84.8cm
20.1in/
51.1cm
IRHS34-230 230V ~ 16 A, 50/60 Hz SHUKO,16AMP
(as of 11/3/14)IEC,16AMP
IRHS34-240 240V ~ 16 A, 50/60 Hz NEMA6-20P
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IRHS42
Shipping Weight 187lbs/84.8kg
Model Electrical Plug H W D
IRHS42-208 208V ~ 12 A, 50/60 Hz NEMA6-15P
25.3in/
64.3cm
19.3in/
49.0cm
20.1in/
51.1cm
IRHS42-230 230V ~ 12 A, 50/60 Hz SHUKO,16AMP
(as of 11/3/14)IEC,16AMP
IRHS42-240 240V ~ 12 A, 50/60 Hz NEMA6-15P
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REMOVAL AND REPLACEMENT OF PARTS
EQUIPMENT USED IN THESE INSTRUCTIONS
• Phillipsscrewdriver
• #1precisionscrewdriver
• Flat-headscrewdriver
• Needle-nosepliers
• 11/16"open-endwrench
• 11/32"nutdriverorsocket
• 1/4"nutdriverorsocket
• Tiewraps
• ESDWristStrap
• Aluminumtape
• Ohmmeter
• Heattransfercompound
• Cleangloves/cloths/towels
ELECTRICAL LOCKOUT/TAGOUT PROCEDURE
WARNING
BEFORE PERFORMING ANY SERVICE THAT
INVOLVES ELECTRICAL CONNECTION OR
DISCONNECTION AND/OR EXPOSURE
TO ELECTRICAL COMPONENTS, ALWAYS
FOLLOW THE ELECTRICAL LOCKOUT/TAGOUT
PROCEDURE. DISCONNECT ALL CIRCUITS.
FAILURE TO COMPLY CAN CAUSE PROPERTY
DAMAGE, INJURY OR DEATH.
TheElectricalLOCKOUT/TAGOUTProcedureisusedto
protectpersonnelworkingonanelectricalappliance.
Beforeperforming anymaintenanceorservicethat
requires exposure to electrical components, follow
thesesteps:
1. Inelectricalbox,placeappliancecircuitbreaker
intoOFFposion.
2. Placealockorotherdeviceonelectricalboxcover
topreventsomeonefromplacingcircuitbreaker
ON.
3. Placeatagonelectricalboxcovertoindicatethat
appliancehasbeendisconnectedforserviceand
powershouldnotberestoredunltagisremoved
bymaintenancepersonnel.
4. Disconnectappliancepowercordfromelectrical
outlet.
5. Placeatagonthecordtoindicatethatunithas
beendisconnectedforserviceandpowershould
notberestoredunltagisremoved.
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ESD WRIST STRAP
Electrostac Discharge (ESD) is one of the biggest
dangerstocomponentsinelectronicdevices.AnESD
wriststrapallowsanyaccumulated stacchargeto
dispersesafelythroughitscable,ratherthanthrough
stac-sensivecomponentssuch as unitcomputer-
relatedcomponents.
1. PlacetheESDwriststraparoundyourwrist.The
wriststrapshouldbenexttoyourskin,soitneeds
tobeplacedunderanyclothes.
2. Tightenthewriststrapsothattheaachedmetal
platemaintainsgoodcontactwithyourskin.Do
notoverghtenasthewriststrapshouldnotbe
uncomfortable.
3. Connect the cable to the wrist strap if it is
disconnected.Thecableshouldbesecurelyclipped
inplacetomaintainagoodconnecon.
4. Placetheunit’sPowerSwitchintheOFFposion
andfollowtheproperLockout/Tagoutprocedures.
5. Connectthealligatorclipontheotherendofthe
cabletoametalsurfaceontheunit.Thiscreatesa
paththroughwhichanybuilt-upstacchargecan
safelyowwithoutcausinganydamage.Abuilt-in
highvalueresistorensuresthechargeleaksaway
inacontrolledmanner,andprotectstheuser.
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DECK ASSEMBLY COMPONENTS
MENU BA RS
TheMenuBarsholdtheKeypadDisplaysthatcontrol
andmonitortheperformanceofeachheangwell.The
quantyvaries(dependingonmodel)andarelocated
onthefrontandbackfacesoftheunit.
TOOLS REQUIRED: Phillips screwdriver; Flat-head
screwdriver
1. Placetheunit’sPowerSwitchintheOFFposion
andfollowtheproperLockout/Tagoutprocedures.
2. RemoveandretainthescrewssecuringtheControl
SideCoverandremovethecover.
3. RemoveandretainscrewsoftheaectedMenu
Barandpullawayfromthefaceoftheunit.Itis
notnecessary,butrecommended,tocompletely
removetheMenuBarfromtheunit.
4. Mark and disconnect the aected Menu Bar’s
molexconnectorinsidethecontrolcompartment.
5. If it is necessary to reuse the exisng Keypad
DisplaysinareplacementMenuBar:
a. Removeandretainthetwo(2)screwssecuring
theMenuBarBackChannelandpryoutofthe
formerMenuBar.
b. A Keypad Spacer is aached to the rear of
eachKeypadDisplaywithdouble-sidedtape.
CarefullypryoandremovetheKeypadSpacer
fromtheaectedKeypadDisplay(s).Thiswill
free-uptheMenuBarHarness.
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c. Disconnect the aected Keypad Display(s)
electrical connector from the Menu Bar
Harness.
d. TheKeypadDisplaysareaachedtotheMenu
Barwithdouble-sidedgluedots.Carefullypry
oandremovetheaectedKeypadDisplay
fromtheMenuBar.
e. Carefully scrape any remaining adhesive
residuefromtheinsideoftheMenuBar.
RESTORE
6. Carefullyplace theKeypadDisplaysinplace on
theinteriorsideofthereplacementMenuBar.If
reusingtheKeypadDisplays,itmaybenecessary
touseaddionaldouble-sidedtapetosecurethe
KeypadDisplaystotheMenuBar.
7. Connect the replacement Menu Bar Harness’
molexconnectorinthecontrolcompartment.
8. ReplacetheKeypadSpacer, overthe MenuBar
Harness,totherearoftheKeypadDisplay(s).
9. ReinstallMenuBarBackChannelusingitsscrews.
10. ReinstalltheMenuBarusingitsscrews.
11. ReplacetheControlSideCoverandsecurewith
itsscrews.
12. Restore power to the unit and test for proper
funcon.
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KEYPAD DISPLAYS
The Keypad Displays control and monitor the
performanceofeachheangwell.Theyarelocated
inside of the Menu Bar(s) and the quanty varies
(dependingonmodel).
TOOLS REQUIRED: Phillips screwdriver; Flat-head
screwdriver
1. Placetheunit’sPowerSwitchintheOFFposion
andfollowtheproperLockout/Tagoutprocedures.
2. RemoveandretainthescrewssecuringtheControl
SideCoverandremovethecover.
3. Disconnect the affected Menu Bar’s molex
connectorinsidethecontrolcompartment.
4. Remove and retain screws of the Menu Bar
containingtheaectedKeypadDisplayandpull
awayfromthefaceoftheunit.Itisnotnecessary,
but recommended, to completely remove the
MenuBarfromtheunit.
5. Remove and retain the screws securing the Menu
BarBackChannelfromthefrontoftheMenuBar
andpryoutoftheMenuBar.
6. AKeypadSpacerisaachedtotherearofeach
KeypadDisplaywithdouble-sidedtape.Carefully
pryoandremovetheKeypadSpacerfromthe
aectedKeypadDisplay(s).Thiswillfree-upthe
MenuBarHarness.
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7. Disconnect the affected Keypad Display(s)
electricalconnectorfromtheMenuBarHarness.
8. The Keypad Displays are aached to the Menu
Bar with double-sided glue dots. Carefully pry
oandremovetheaectedKeypadDisplayfrom
theMenuBar.
9. Carefullyscrapeanyremainingadhesiveresidue
fromtheinsideoftheMenuBar.
RESTORE:
10. Peelotheadhesivecoverfromthegluedotsand
placeonthereplacementKeypadDisplay.
11. Peel o the other adhesive cover from the glue
dotsandcarefullyposionthereplacementKeypad
DisplayinplaceontheinteriorsideoftheMenuBar.
12. ReconnecttheaectedKeypadDisplay(s)electrical
connectortotheMenuBarHarness.
13. ReplacetheKeypadSpacer,overtheMenuBar
Harness,totherearoftheKeypadDisplay(s).
14. Reinstall the Menu Bar Back Channel using its
screws.
15. ReinstalltheMenuBarusingitsscrews.
16. Restore power to the unit and test for proper
funcon.
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16 SM-PH-IH-0003
RTD (TEMPERATURE) SENSORS
The RTD Sensors monitor the temperature of the
heangwells.Theyareaxedtotheboom-centerof
eachHeatElement,andthequantyvaries(depending
onmodel).
TOOLS REQUIRED: Phillips screwdriver; Aluminum
tape; Tie wraps
1. Placetheunit’sPowerSwitchintheOFFposion
andfollowtheproperLockout/Tagoutprocedures.
2. Removeanypansandcoversonthelevel(s)being
removed.
3. RemoveandretainthescrewssecuringtheTop
Panelandremovethecover.
4. RemoveandretainthescrewssecuringtheControl
SideCoverandremovethecover.
NOTE: If the RTD Sensor to be replaced is on a lower
level, start from the top and repeat the
following four steps for each level above the
desired level.
5. Mark,removetheewraps,anddisconnectthe
wires for the RTD Sensors from the RTD board in
theControlCompartment.
6. Mark, remove the e wraps, and disconnect
the wires for the Emier (IR Bulb) Sockets and
Heat Elements from the Relays in the Control
Compartment.
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7. Removethefour(4)screws(2infront,2inback)
securingthelinerdeckassemblytotheunit.
8. Carefullyli the enreliner deck assembly out
throughthetopoftheunit.Thismayrequiretwo
people, depending on the locaon of the IRHS
unit.Thoughnotrequiredtodoso,removingthe
level’sIRglassframeassembly(instruconsare
containedintheEmierinstrucons)willlighten
theweightofthelinerdeckassemblyandmake
iteasierforonepersontoaccomplishthistaskif
theIRHSislocatedinanelevatedlocaonorhas
limitedaccess.
NOTE: It will be necessary to feed the RTD Sensor,


not to damage any of the wires.
9. Invertthelinerdeckassemblyupside-down,then
removeandretaintheinsulaon.
10. TheRTDSensorisaachedtotheheatelement
withdouble-sidedadhesivetapeandcoveredwith
aluminumtape.Carefullypryoandremovethe
aectedRTDSensorfromtheHeatElement.
RESTORE:
11. Peel off the adhesive tape cover from the
replacement RTD Sensor and press in place on
theheatelement.Replacealuminumtapecover.
12. Feed the Heat Element and RTD Sensor wires in the
direconofandthroughthecontrolcompartment
bushingsandreplacetheinsulaon.

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13. Invert the liner deck assembly right-side up.
WhilefeedingtheRTDSensor,Emier,andHeat
Element wires through the appropriate control
compartment bushings, carefully slide the liner
deckassembly intotheunit,takingcauonnot
todamageanyofthewires.
NOTE: This may require two people, depending on

14. Reconnectandewrapallpreviouslydisconnected
wiresandconnectorsinthecontrolcompartment.
15. ReplacetheControlSideCoverandsecurewith
itsscrews.
16. ReplacetheTopPanelandsecurewithitsscrews.
17. Restore power to the unit and test for proper
funcon.
HIGH LIMIT THERMOSTATS
TheHighLimitThermostatsmonitorwelltemperatures
andservesasanemergencycircuitinterrupterincase
ofinadvertentoverheang.Thereisoneperlevel,and
areaxedtotheboom-centerofeachheatsink.
TOOLS REQUIRED: Phillips screwdriver; Heat transfer
compound; Tie wraps
1. Placetheunit’sPowerSwitchintheOFFposion
andfollowtheproperLockout/Tagoutprocedures.
2. Removeanypansandcoversonthelevel(s)being
removed.
3. RemoveandretainthescrewssecuringtheTop
Panelandremovethecover.

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4. RemoveandretainthescrewssecuringtheControl
SideCoverandremovethecover.
NOTE: If the High Limit Thermostat to be replaced is
on a lower level, start from the top and repeat
the following four steps for each level above
the desired level.
5. Mark,removetheewraps,anddisconnectthe
wires for the RTD Sensors from the RTD board in
theControlCompartment.
6. Mark, remove the e wraps, and disconnect
the wires for the Emier (IR Bulb) Sockets and
Heat Elements from the Relays in the Control
Compartment.
7. Removethefour(4)screws(2infront,2inback)
securingthelinerdeckassemblytotheunit.
8. Carefullyli the enreliner deck assembly out
throughthetopoftheunit.Thismayrequiretwo
people, depending on the locaon of the IRHS
unit.Thoughnotrequiredtodoso,removingthe
level’sIRglassframeassembly(instruconsare
containedintheEmierinstrucons)willlighten
theweightofthelinerdeckassemblyandmake
iteasierforonepersontoaccomplishthistaskif
theIRHSislocatedinanelevatedlocaonorhas
limitedaccess.
NOTE: It will be necessary to feed the RTD Sensor,


not to damage any of the wires.

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9. Invertthelinerdeckassemblyupside-down,then
removeandretaintheinsulaon.
10. Markanddisconnectthespadeterminalsforthe
aectedHighLimitThermostat.
11. Removeandretainthetwo(2)11/32"nutssecuring
theHigh LimitThermostattotheheatsinkand
removetheHighLimitThermostat.
12. Cleanthemounngsurfaceofanyresidualheat
transfercompound.
RESTORE:
13. Applyheattransfercompoundtothemounng
surfaceofthereplacementHighLimitThermostat.
14. InstallthereplacementHighLimitThermostatand
securewithitsnuts.
15. Reattach the High Limit Thermostat spade
terminals.Besuretoreapplythetapethathelps
secure the spade terminals to the High Limit
Thermostat.
16. Feed the Heat Element and RTD Sensor wires in the
direconofandthroughthecontrolcompartment
bushingsandreplacetheinsulaon.
17. Invert the liner deck assembly right-side up.
WhilefeedingtheRTDSensor,Emier,andHeat
Element wires through the appropriate control
compartment bushings, carefully slide the liner
deckassembly intotheunit,takingcauonnot
todamageanyofthewires.
NOTE: This may require two people, depending on

18. Reconnectandewrapallpreviouslydisconnected
wiresandconnectorsinthecontrolcompartment.
19. ReplacetheControlSideCoverandsecurewith
itsscrews.
20. ReplacetheTopPanelandsecurewithitsscrews.
21. Restore power to the unit and test for proper
funcon.