Fri-Jado HOT DELI 3 User manual

Service Manual Hot Deli HD3/4/5/7 form 9123549 rev.03/2017
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SERVICE MANUAL
- NOTICE -
This manual is prepared for the use of trained Service Technicians and should not
be used by those not properly qualified. If you have attended a trianing for this
product, you may be qualified to perform all the procedures in this manual.
This manual is not intended to be all encompassing. If you have not attended
training for this product, you should read, in its entirety, the repair procedure you
wish to perform to determine if you have the necessary tools, instruments and
skills required to perform the procedure. Procedures for which you do not have
the necessary tools, instruments and skills should be performed by a trained
technician.
Reproduction or other use of this Manual, without the express written consent of
Fri-Jado, is prohibited.
HD 5 curved on underframe
HOT DELI 3/4/5/7 MERCHANDISERS
MODELS
Premium curved and square
Essential curved and square
Self-Service curved and square
HD 5 square on underframe

Service Manual Hot Deli HD3/4/5/7 form 9123549 rev.04/2017
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TABLE OF CONTENTS
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Service Manual Hot Deli HD3/4/5/7 form 9123549 rev.04/2017 Page 3
TABLE OF CONTENTS
Versions
Version Issue date
dd/mm/yy
Remarks
06/2014 01/06/2014 Textual changes. Model updating.
05/2015 01/05/2015 Curved models adapted. Square models added.
03/2017 01/03/2017 New ERC 211 thermostat added. New blower added. New electric
diagrams. Various updates.
04/2017 08/05/2017 Pos 1-21 added in explodedviews

Service Manual Hot Deli HD3/4/5/7 form 9123549 rev.04/2017
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TABLE OF CONTENTS
Index .......................................................................................................................................................... 4
General technical data.............................................................................................................................. 6
Technical data ....................................................................................................................................... 6
Programming instructions........................................................................................................................ 7
Display Essential and Self Service model .............................................................................................. 7
Display Essential and Self Service model till serial number 100080408.............................................. 8
Display Premium model......................................................................................................................... 9
Display Humidified model (Continued).............................................................................................. 10
Removal and replacement of parts ...................................................................................................... 11
Panels left and right back side............................................................................................................ 11
Fuse and fuse holder ........................................................................................................................... 11
Contactor.............................................................................................................................................. 12
Water level control, electronic............................................................................................................ 12
Blower, left hand side.......................................................................................................................... 12
Heating element, left hand side......................................................................................................... 13
PT 1000 sensor ..................................................................................................................................... 13
Ring core transformer 230-208V......................................................................................................... 13
Water level sensor ............................................................................................................................... 14
Heating element water tray................................................................................................................ 14
I/O Board .............................................................................................................................................. 15
Display board ....................................................................................................................................... 15
Keypad.................................................................................................................................................. 16
Thermostat Danfoss EKC 102A or ERC 211......................................................................................... 17
Sensor thermostat................................................................................................................................ 18
Tumble switch light and heating ........................................................................................................ 18
Blower right hand side........................................................................................................................ 19
Heating element right hand side........................................................................................................ 19
Front grip magnets curved model ...................................................................................................... 20
Curved glass ......................................................................................................................................... 20
Curved glass (alternative procedure when torques key is not available) ............................ 21
Gas spring curved model ..................................................................................................................... 22
Lamp holder......................................................................................................................................... 22
Ceramic element.................................................................................................................................. 23
Blower in top ....................................................................................................................................... 24
Profile sliding door in top ................................................................................................................... 24
Gas spring square model..................................................................................................................... 25
Front glass door square model ........................................................................................................... 26
Protection profile in front (bumper) .................................................................................................. 27
Side plate left and right, front side .................................................................................................... 27
Drain..................................................................................................................................................... 27
Changing Danfoss EKC to ERC thermostat......................................................................................... 28
INDEX

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TABLE OF CONTENTS
Electrical tests and service procedures.................................................................................................. 30
PT 1000 sensor test Premium (Humidified version) ........................................................................... 30
Heating element test........................................................................................................................... 31
Adjusting Danfoss ERC 211 thermostat.............................................................................................. 32
Danfoss ERC 211 Settings .................................................................................................................... 33
Adjusting Danfoss EKC 102A thermostat till serial number 100080408........................................... 34
Danfoss EKC 102A Settings till serial number 100080408 ................................................................. 35
Product temperature probe setings Danfoss ERC 211....................................................................... 36
Product Temperature probe settings Danfoss EKC 102A ................................................................. 37
till serial number 100080408............................................................................................................... 37
Control location Essential (full serve) and self serve ......................................................................... 38
Control location Essential and self serve till serial number 100080408 ........................................... 39
Control panel Premium (humidified) ................................................................................................. 39
Troubleshooting ...................................................................................................................................... 40
Hot Deli 3/4/5/7 Essential (Full serve) & self serve .............................................................................. 40
Hot Deli 3/4/5/7 Premium: HumidIfied/automatic water filling ........................................................ 41
Exploded views & partlists..................................................................................................................... 42
Hot Deli 3-4-5 Self Service Assembly drawing.................................................................................... 42
Hot Deli 3-4-5 Self Service Components drawing .............................................................................. 46
Hot Deli 3-4-5 Essential (Full Service) Assembly drawing .................................................................. 48
Hot Deli 3-4-5 Essential (Full Service) Component drawing.............................................................. 52
Hot Deli 3-4-5 Premium (Humidified) Assembly drawing ................................................................. 54
Hot Deli 3-4-5 Premium (Humidified) Components drawing............................................................ 58
Exploded views & partlists..................................................................................................................... 62
Hot Deli 3-4-5 Self Service Square Assembly drawing ....................................................................... 62
Hot Deli 3-4-5 Self Service Square Components drawing ................................................................. 66
Hot Deli 3-4-5 Essential Square (Full Service) Assembly drawing ..................................................... 68
Hot Deli 3-4-5 Essential Square (Full Service) Component drawing ................................................. 72
Hot Deli 3-4-5 Premium Square (Humidified) Assembly drawing..................................................... 74
Hot Deli 3-4-5 Premium Square (Humidified) Components drawing ............................................... 78
Electrical diagrams.................................................................................................................................. 82
Circuit diagram HD 3 Essential (Full sevice) & self service ................................................................. 82
Circuit diagram HD 3 Essential (Full sevice) & self service till serial number 100080408................. 83
Wiring diagram HD 3 Essential (Full service) & self service ............................................................... 84
Wiring diagram HD 3 Essential (Full service) & self service till serial nr. 100080408........................ 85
Circuit diagram HD 3 Premium (Humidified) ..................................................................................... 86
Wiring diagram HD 3 Premium (Humidified) .................................................................................... 87
Circuit diagram HD 3 Premium (Humidified), automatic water filling ............................................ 88
Wiring diagram HD 3 Premium (Humidified), automatic water filling............................................ 89
Circuit diagram HD 3 Premium (Humidified) with probe ................................................................. 90
Circuit diagram HD 3 Premium (Humidified) with probe, autom. water filling.............................. 91
Circuit diagram HD 4 Essential (Full service) & self service................................................................ 92
Circuit diagram HD 4 Essential (Full service) & self service till serial number 100080408 ............... 93
Wiring diagram HD 4 Essential (Full service) & self service .............................................................. 94
Wiring diagram HD 4 Essential (Full service) & self service till serial number 100080408............... 95
Circuit diagram HD 4 Premium (Humidified) ..................................................................................... 96
Wiring diagram HD 4 Premium (Humidified) .................................................................................... 97
Circuit diagram HD 4 Premium (Humidified), automatic water filling ............................................ 98
Wiring diagram HD 4 Premium (Humidified), automatic water filling............................................ 99
Circuit diagram HD 4 Premium (Humidified) with probe ............................................................... 100
Circuit diagram HD 4 Premium (Humidified) with probe, autom. water filling............................ 101

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TABLE OF CONTENTS
Circuit diagram HD 5 Essential (Full service) & self service.............................................................. 102
Circuit diagram HD 5 Essential (Full service) & self service till serial number 100080408 ............. 103
Wiring diagram HD 5 Essential (Full service) & self service ............................................................. 104
Wiring diagram HD 5 Essential (Full service) & self service till serial number 100080408............. 105
Circuit diagram HD 5 Premium (Humidified) ................................................................................... 106
Wiring diagram HD 5 Premium (Humidified) .................................................................................. 107
Circuit diagram HD 5 Premium (Humidified), automatic water filling .......................................... 108
Wiring diagram HD 5 Premium (Humidified), automatic water filling.......................................... 109
Circuit diagram HD 5 Premium (Humidified) with probe ............................................................... 110
Circuit diagram HD 5 Premium (Humidified) with probe, autom. water filling............................ 111
Circuit diagram HD 7 Essential (Full service) .................................................................................... 112
Wiring diagram HD 7 Essential (Full service).................................................................................... 113
Circuit diagram HD 7 Premium (Humidified) ................................................................................... 114
Wiring diagram HD 7 Premium (Humidified) .................................................................................. 115
Circuit diagram HD 7 Premium (Humidified), automatic water filling .......................................... 116
Wiring diagram HD 7 Premium (Humidified), automatic water filling.......................................... 117
Circuit diagram HD 7 Premium (Humidified) with probe ............................................................... 118
Circuit diagram HD 7 Premium (Humidified) with probe, autom. water filling............................ 119

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TABLE OF CONTENTS
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GENERAL INFORMATION
Service Manual Hot Deli HD3/4/5/7 form 9123549 rev.03/2017
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GENERAL TECHNICAL DATA
This manual covers the Hot Deli Merchandisers in the models curved and square. The Mer-
chandisers are available in 4 sizes to build-in into an existing counter. Merchandisers will also
be deliverd on an underframe.
The Merchandisers come in 3 models.
• Premium = Full service with humidification.
• Essential = Full service.
• Self-Serve = Self service.
All of the information, illustrations and specifications contained in this manual are based on
the latest product information available at the time of printing.
TECHNICAL DATA
Type HD 3 HD 4 HD 5 HD 7
Power (W) Premium 4600 4900 5100 8600
Power (W) Essential 3700 4000 4200 7700
Power (W) Self Service 3700 4000 4200 -
Fuses needed with power connection
400V, 3N~50...60Hz (3 phases with zero) 3x 16 A 3x 16 A 3x 16 A 3x 16 A
Fuses needed with power connection
230V, 3~50...60Hz (3 phases without zero) 3x 16 A 3x 16 A 3x 16 A 3x 20 A
Fuses needed with power connection
230V, 1N~50...60Hz (1 phase with zero) 32 A 32 A 32 A 50 A
Standard plug from factory CEE-form 5-pole 16 A 16 A 16 A 16 A
Net weight Premium (kg) 157 210 240 272
Net weight Essential (kg) 142 195 225 257
Net weight Self Service (kg) 136 188 217 -
Gross weight Premium (kg) 212 275 315 355
Gross weight Essential (kg) 197 260 300 340
Gross weight Self Service (kg) 191 253 292 -
Height (mm) 960 960 960 960
Width (mm) 1086 1419 1752 2505
Depth (mm) 1058 1058 1058 1058
Tools
• Standard set of tools.
• Metric wrenches, sockets and hex socket key wrenches.
• Multi meter and AC current clamp meter.
• Temperature tester.
• Insulation value tester (Megger).
• Field Service Grounding Kit.

Service Manual Hot Deli HD3/4/5/7 form 9123549 rev.03/2017
PROGRAMMING INSTRUCTIONS
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PROGRAMMING INSTRUCTIONS
Check set temperature
The temperature in the warmer is shown on
the display during use.
1. Press SET key.
The set temperature will be shown on the
display. The measured temperature in the
warmer will again be shown after 10 seconds.
DISPLAY ESSENTIAL AND SELF SERVICE MODEL
Switch on
1. Switch on the heater with switch A6.
2. Switch on the lighting with switch A7.
3. Also switch on the IR emitters with
switch A8 if required.
Switch off
1. Switch off the IR emitter with switch A8.
2. Switch off the lighting with switch A7.
3. Switch off the heating with switch A6.

PROGRAMMING INSTRUCTIONS
Service Manual Hot Deli HD3/4/5/7 form 9123549 rev.03/2017
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Switch on
1. Switch on the heater with switch A6.
2. Switch on the lighting with switch A7.
3. Also switch on the IR emitters with
switch A8 if required.
Switch off
1. Switch off the IR emitter with switch A8.
2. Switch off the lighting with switch A7.
3. Switch off the heating with switch A6.
Check set temperature
The temperature in the warmer is shown on
display A2 during use.
1. Press centre key A4.
The set temperature will be shown on the
display. The measured temperature in the
warmer will again be shown after 20 seconds.
Set the temperature
1. Press centre key A4. The set value will be
shown on the display.
2. Set the required temperature using the
top (A3) and bottom (A5) keys.
3. Press centre key A4 to save.
DISPLAY ESSENTIAL AND SELF SERVICE MODEL TILL SERIAL NUMBER 100080408

DISPLAY PREMIUM MODEL
B1
B2 B3 B4 B5 B6
B7
B8
Service Manual Hot Deli HD3/4/5/7 form 9123549 rev.03/2017
PROGRAMMING INSTRUCTIONS
Page 11
Switch on
1. Keep keys B3 and B4 pressed
simultaneously for 2 seconds.
2. Switch on the lighting with
key B3.
3. Switch on the required IR
emitters with keys B1.
Switch off
1. Keep keys B3 and B5 pressed
simultaneously for 2 seconds.
Check set temperature
The temperature in the warmer is shown on the display B2 during use.
1. Press key B4 or B5 for a short time.
The set temperature will be shown on the display. The measured temperature in the warmer
will be shown again after 10 seconds.
Set the temperature
The temperature is set on 80°C and limited between 30°C and 90°C as standard.
1. Press key B4 or B5 for a short time. The set value will be shown on the display with a dot
behind the value.
2. Wait 5 seconds; you cannot immediately change the setting.
3. Set the required temperature with keys B4 and B5.
4. Wait until the display jumps back to the measured temperature in the warmer.
The adjustment has now been saved.
Topping up the steam tray
You hear a signal as soon as the steam tray requires topping up. Humidification will be
automatically switched off.
1. Press key B7 or B8 to stop the beep signal.
2. Fill the steam tray by three quarters (approx. 6,5 L.) with hot water to prevent large
temperature differences.
Humidification will restart automatically based on the previously set adjustment
after topping up. You do not have to set it again.

DISPLAY HUMIDIFIED MODEL (CONTINUED)
PROGRAMMING INSTRUCTIONS
Service Manual Hot Deli HD3/4/5/7 form 9123549 rev.03/2017
Page 12
Set the humidifier
Water consumption will amount to approx. 1.2 liter per hour in relation to the maximum
setting. Indication bar B6 indicates the humidification degree.
• 3/3, humidification 100%.
• 2/3, humidification 67%.
• 1/3, humidification 33%.
• 0, humidification switched off. The bottom segment of the indication bar will flash every
10 seconds.
1. Set the required humidification level with the keys B7 and B8.
Set the IR emitters
1. Press keys B1 for a short time to switch on or off the related IR emitter. The indication
light on top of the key will light up if the emitter is switched on.
Set the Offset
With the offset you only change the temperature indication on the display. The set point will
not be changed.
1. Press both temperature keys (B4 and B5) for 5 sec.
2. The offset temperature now appears on the screen with a flashing dot behind the value.
3. Use the temperature keys B4 and B5 to change the offset temperature.
4. After 5 seconds of no keys being pressed the system will return to normal operation.

REMOVAL AND REPLACEMENT OF PARTS
Service Manual Hot Deli HD3/4/5/7 form 9123549 rev.03/2017 Page 13
WARNING: Disconnect the electrical power to the machine
at the main circuit box. Place a tag on the circuit box indica-
ting the circuit is being serviced.
1. Remove the socket head screws that se-
cure the panel to the frame.
2. Turn panel towards yourself.
3. Reverse the procedure to install.
Note: The panels can be lifted out from the
hinges. First lift out the hinge on the middle
panel.
1. Remove the left side panel according
prior procedure.
2. Remove the screws that secure the cover
plate and turn cover plate towards
yourself.
3. Disconnect the wiring from the fuse
housing.
4. Remove the flat nut that secures the
housing of the fuse and remove the
housing.
5. Reverse the procedure to install.
REMOVAL AND REPLACEMENT OF PARTS
PANELS LEFT AND RIGHT BACK SIDE
FUSE AND FUSE HOLDER

REMOVAL AND REPLACEMENT OF PARTS
Service Manual Hot Deli HD3/4/5/7 form 9123549 rev.03/2017
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1. Remove the left side panel and the cover
plate according prior procedure.
2. Remove the bolt that secures the electric
panel and remove this panel.
3. Cut the wiring of the blower.
4. Remove the bolts that secure the
clamping profiles on the blower and
remover the profiles.
5. Remove the blower by sliding this
towards yourself.
6. Reverse the procedure to install.
Note: you have to connect the wiring again
with a butt splice.
BLOWER, LEFT HAND SIDE
1. Remove the left side panel and the cover
plate according prior procedure.
2. Disconnect the lead wires to the
contactor.
3. Push the locking tab down with a screw-
driver (see arrow) and lift out to remove
the contactor from the mounting brack-
et.
4. Reverse the procedure to install.
CONTACTOR
1. Remove the left side panel and the cover
plate according prior procedure.
2. Disconnect the wiring of the electronic
control.
3. Remove the 2 screws that secure the
control and remove the control.
4. Reverse the procedure to install.
WATER LEVEL CONTROL, ELECTRONIC

REMOVAL AND REPLACEMENT OF PARTS
Service Manual Hot Deli HD3/4/5/7 form 9123549 rev.03/2017 Page 15
1. Remove the left side panel and the cover
plate according prior procedure.
2. Disconnect the wiring from the element.
3. Remove the pans and frame out of the
cabinet.
4. Remove the 2 nuts and rings that secure
the element and remove the element.
5. Reverse the procedure to install.
HEATING ELEMENT, LEFT HAND SIDE
1. Remove the left side panel and the cover
plate according prior procedure.
2. Remove the bolt that secures the sensor
and remove the sensor.
3. Disconnect the wiring.
4. Reverse the procedure to install.
1. Remove the left side panel and the cover
plate according prior procedure.
2. Remove the wiring of the transformer.
3. Remove the screw that secures the trans-
former and remove the transformer.
4. Reverse the procedure to install.
PT 1000 SENSOR
RING CORE TRANSFORMER 230-208V

REMOVAL AND REPLACEMENT OF PARTS
Service Manual Hot Deli HD3/4/5/7 form 9123549 rev.03/2017
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1. Remove the left side panel and the cover
plate according prior procedure.
2. Remove the water tray door and the
water tray.
3. Disconnect the wiring of the sensor on
the electronic water level control
(2 middle pins).
4. Remove the 2 nuts and screws that secure
the sensor bracket and remove the sensor.
5. Reverse the procedure to install.
1. Remove the water tray door, the water
tray and the pans and frame inside the
cabinet.
2. Remove the left and right hand panel on
the backside according prior procedures.
3. Disconnect the wiring from the elements.
4. Cut the sealant between cover housing
and the inside back plate in the cabinet
see arrow).
5. Remove the 2 bolts that secure the cover
housing of the elements.
6. Slide the cover housing towards customer
side and lift it out.
7. Remove the nuts and rings that secure the
heating elements and remove the
element(s).
8. Reverse the procedure to install.
Note: Apply sealant between cover housing
and the inside back plate in the cabinet.
WATER LEVEL SENSOR
HEATING ELEMENT WATER TRAY

REMOVAL AND REPLACEMENT OF PARTS
Service Manual Hot Deli HD3/4/5/7 form 9123549 rev.03/2017 Page 17
1. Remove the right side panel according
prior procedure.
2. Remove the nuts that secure the cover
plate and remove the cover plate.
3. Disconnect all wiring and the flat cable.
4. Remove the board from the clips by
squeezing the clips together.
5. Reverse the procedure to install.
I/O BOARD
1. Remove the right side panel according
prior procedure.
2. Remove the nuts that secure the cover
plate and remove this plate.
3. Remove the nuts that secure the mount-
ing plate and remove this plate.
4. Disconnect the grey flat cable and the flat
cable from the keypad.
5. Remove the nuts that secure the board
and remove the board.
6. Reverse the procedure to install.
Note: When installing a new board, ensure
that the jumper on the new board is set the
same as on the old board (°C/°F).
DISPLAY BOARD
jumper

REMOVAL AND REPLACEMENT OF PARTS
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Page 18
1. Remove the right side panel according
prior procedure.
2. Remove the nuts that secure the cover
plate and remove this plate.
3. Remove the nuts that secure the
mounting plate and remove this plate.
4. Remove the grey flat cable and the flat
cable from the keypad.
5. Remove the nuts that secure the display
board and remove the board.
6. Remove the nut that secures the earth
cable on the panel and remove the cable.
7. Remove the back panel by lifting it out of
the hinges.
8. Remove the nut that secures the back
plate of the keypad and remove this
plate.
9. Remove the keypad and clean the surface
with a degreaser.
10.Fasten the back plate back on the panel
and apply the keypad.
11.Apply acid free sealant around the green
flat cable.
12.Reverse the procedure to install.
Note: It is also possible to order a complete
back plate with keypad.
KEYPAD

75.4
REMOVAL AND REPLACEMENT OF PARTS
Service Manual Hot Deli HD3/4/5/7 form 9123549 rev.03/2017 Page 19
1. Remove the left and right hand panel ac-
cording prior procedures.
2. Remove the left and right back panel by
lifting them out of the hinges.
3. Remove the socket screws that secure the
middle panel and turn the panel towards
yourself.
4. Loosen the blocking clips on the sides of
the thermostat and remove the thermo-
stat.
5. Disconnect the wiring.
6. Reverse the procedure to install.
Note: Set all parameters in the new thermo-
stat.
THERMOSTAT DANFOSS EKC 102A OR ERC 211
ERC 211

REMOVAL AND REPLACEMENT OF PARTS
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1. Remove the middle panel according prior
procedures.
2. Disconnect the wiring of the sensor on
the thermostat.
3. Remove the socket head screws that
secure the sensor holder and remove the
holder.
4. Remove sensor from holder.
5. Reverse the procedure to install.
Note: The place of the sensor is the same for
the Essential and self service models.
SENSOR THERMOSTAT
1. Remove the middle panel according prior
procedures.
2. Disconnect the wiring.
3. Remove the switch by pushing the clamps
on both sides.
4. Reverse the procedure to install.
TUMBLE SWITCH LIGHT AND HEATING