Henny Penny HCS-2 User manual

TECHNICAL MANUAL
Henny Penny
Humidified Counter Warmer
Model HCW-2
Model HCS-2
Model HCW-3
Model HCW-5
Model HCS-5
Model HCW-8

Model HCS-2,HCW-3/HCW-5/HCW-8
TABLEOFCONTENTS
Section Page
Section1. TROUBLESHOOTING ............................................................................................... 1-1
1-1. Introduction......................................................................................................... 1-1
1-2. Safety ................................................................................................................. 1-1
1-3. Troubleshooting ................................................................................................... 1-1
Section2. MAINTENANCE ........................................................................................................ 2-1
2-1. Introduction......................................................................................................... 2-1
2-2. TestInstruments .................................................................................................. 2-1
2-3. LightBulb ........................................................................................................... 2-1
2-4. Fuse.................................................................................................................... 2-2
2-5. CleaningWaterStrainer ....................................................................................... 2-2
2-6. WaterStrainer(Replacement) .............................................................................. 2-4
2-7. WaterValve ........................................................................................................ 2-4
2-8. FloatSwitch ........................................................................................................ 2-6
2-9. LightSwitch ........................................................................................................ 2-7
2-10. PowerSwitch...................................................................................................... 2-8
2-11. Water Control Switch .......................................................................................... 2-9
2-12. InfiniteSwitch...................................................................................................... 2-9
2-13. Thermostat .......................................................................................................... 2-10
2-14. IndicatingLight .................................................................................................... 2-11
2-15. Thermometer....................................................................................................... 2-12
2-16. Contactor............................................................................................................ 2-13
2-17. TerminalBlock .................................................................................................... 2-14
2-18. WaterPan Heater................................................................................................ 2-15
2-19. RadiantHeater .................................................................................................... 2-16
2-20. LightSocket........................................................................................................ 2-17
2-21. HighLimitSwitch ................................................................................................ 2-17
2-22. Conversion.......................................................................................................... 2-18
2-23. WiringDiagrams .................................................................................................. 2-21
Section3. PARTS INFORMATION ............................................................................................. 3-1
3-1. Introduction......................................................................................................... 3-1
3-2. GenuineParts ...................................................................................................... 3-1
3-3. Howto Find Parts............................................................................................... 3-1
3-4. How to Order ..................................................................................................... 3-1
3-5. Prices.................................................................................................................. 3-2
3-6. Delivery .............................................................................................................. 3-2
3-7. Warranty ............................................................................................................. 3-2
3-8. RecommendedSpareParts for Distributors.......................................................... 3-2
3-9. PartsList............................................................................................................. 3-4
206 i
FM06-016
Revised1-26-09

ii 703

Model HCS-2,HCW-3/HCW-5/HCW-8
SECTION 1. TROUBLESHOOTING
1-1. INTRODUCTION Thesectionprovidestroubleshootinginformationin the formofan
easy to read table.
Ifaproblem occursduringthe firstoperationof a newcabinet,
rechecktheInstallation section oftheOperator’sManual.
Beforetroubleshooting,alwaysrecheck theOperationsectionof
theOperator’s Manual.
103 1-1
1-2. SAFETY Whereinformationisofparticularimportanceor is safetyrelated,
the words NOTICE, CAUTION, or WARNING are used.Their
usageis described below.
SAFETYALERTSYMBOLisusedwithDANGER,
WARNING,or CAUTIONwhichindicates a personalinjury
typehazard.
NOTICEisusedtohighlightespeciallyimportantinformation.
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.
ThewordWARNINGis used to alert youtoaprocedure,
thatif notperformed properly,mightcause personal
injury.
1-3. TROUBLESHOOTING Toisolateamalfunctionproceedasfollows:
1. Clearly definetheproblemor symptom andwhenitoccurs.
2. Locate theprobleminthetroubleshootingtable.
3. Review allpossiblecauses, thenoneat atimework
throughthelistofcorrectionsuntiltheproblemissolved.
Ifmaintenance procedures arenotfollowed correctly,
injuriesand/orproperty damagecouldresult.

Model HCS-2,HCW-3/HCW-5/HCW-8
PROBLEM CAUSE CORRECTION
THERMOMETER
A. Readingdoes •Thermometerbulbisnotin •Insert bulbinblock
notmatch holdingblock
actual
temperature •Faultythermometer •Replace perThermometer
section
OPERATIONS
A. Product not •Doors are not kept closed •Keepdoors closed when
holding possible
temperature
•Productheldtoo long •Onlyholdproductfor
recommendedtimes
•Water temperaturetoolow •Check water heatingsystem
perWater Pan Heatersection
•Radiantheattoo low •Turntohighersetting
•Radiantheatnotworking •Checkradiant heatsystem per
RadiantHeatersection
•Lightbulbsout •Replace asrequired, per
LightBulbsection
B. Doors are •Doorsleftopen toomuch •Keep doorsclosed when
fogging allowingdoorsto cooland possible
causecondensation
•Radiantheatnothighenough •Turntohighersetting
•Radiantheatnotworking •Checkradiant heaterper
RadiantHeatersection
•Water temperaturetoohigh •Seerecommendedsettings
andtemperatures
1-2 103
1-3. TROUBLESHOOTING(Continued)

Model HCS-2,HCW-3/HCW-5/HCW-8
PROBLEM CAUSE CORRECTION
WATERSYSTEM
A. Water will •Faultyfloatswitch •Check float switchper
notfill FloatSwitchsection
•Faultywatercontrolswitch •Checkwatercontrol switch
perWaterControlSwitch
section
•Faultywatervalve •Checkwater valve per
WaterValvesection
•Water supplyhasbeen shut •Checkthewater supply
offordisconnected
LIGHTING
A. Lightswill •Defectivefuse •Check per Fuse section
notturnon
•Faultylightswitch •Checklightswitchper
LightSwitchsection
•Noneutralsuppliedinfield •Check fieldwiringtobe sure
wiring a trueneutral has been
connected
•Looseordefectivewiring •Checkwiringand repairand
replaceifnecessary
B. Notalllightson •Faultylightbulbs •Replacewithrecommended
bulbperLightBulbsection
•Faultylightswitch •Checklightswitchper
LightSwitchsection
103 1-3
1-3. TROUBLESHOOTING(Continued)

Model HCS-2,HCW-3/HCW-5/HCW-8
PROBLEM CAUSE CORRECTION
HEATING SECTION
A. Water will •Faultycontactor •Replacecontactor per
notheat Contactorsection
•Faultythermostat •Checkthermostatper
Thermostatsection
•Faultyhighlimitswitch •Checkhighlimitswitchper
HighLimitSwitchsection
B. Water will not •Loworimpropervoltage •Use ameter andcheck wall
reachdesired voltageversus dataplate
temperature
•Faultywaterheatingelement •Checkheating elements per
Water Heatersection
•Wiring •Checkfor looseconnections
orfaulty wiresandcorrect or
replaceas necessary
•Bunpans arenot overwater •Place perforatedbun pans
overwater
C. Radiant heat •Faultyinfiniteregulator •Replaceinfiniteregulatorper
notworking InfiniteSwitchsection
•Faultypowerswitch •Checkpower switchper
PowerSwitchsection
•Faultyradiantheater •Check heater per
RadiantHeatersection
1-4 103
1-3. TROUBLESHOOTING(Continued)

Model HCS-2,HCW-3/HCW-5/HCW-8
SECTION 2. MAINTENANCE
2-1. INTRODUCTION Thissection providesproceduresforthe checkoutandreplacement
ofthevariouspartsused withinthecabinet.Beforereplacingany
parts,referto theTroubleshootingsection. It willaidyou indeter-
miningthecauseofthemalfunction.
2-2. TEST INSTRUMENTS You mayusetwo test instrumentstocheck the electriccomponents.
1. Acontinuitylight
2. Anohmmeter.
Whenthemanualreferstothecircuitbeingclosed,thecontinuity
lightwillbeilluminatedortheohmmetershouldreadzerounless
otherwisenoted.
Whenthemanualreferstothecircuitbeingopen,thecontinuitylight
willnotilluminateortheohmmeterwillread1(one)orinfinite
resistance.
Acontinuitytester cannotbeused tocheckcoils.
2-3. LIGHTBULB
Lightbulbsand glass maybehot. Severe burns could
result.
1. Remove theglasspanelbycarefullypushing uponbackof
panelandslidingawayfromyou.Thepanelwillfallinto
yourhand.
2. Removethelightbulb.
103 2-1

Model HCS-2,HCW-3/HCW-5/HCW-8
2-3. LIGHTBULB 3. Replace thelightbulbwithaWestinghouse#60A19/35,
(Continued) 130Volt bulb.
Ifthisbulb isnotavailable, a standard60watt bulbwillwork
untilalonglifebulbcanbeobtained.
4. Replace theglasspanel.
2-4. FUSE
Ifalllightbulbsgooutatonce:
1. Turnoffthelightswitch.
2. Locate thefuseholder, nexttolight switch,andremove the cap
byturningitcounterclockwise.
3. Pullthefusefromtheholder.
4. Replace thefusewith anew 15ampfuse.
5. Replace thecap.
6. Turnonthelights.
2-5. CLEANINGWATER 1. Removeelectricalpowersupplied to thecabinet.
STRAINER
Toavoidelectrical shock orpropertydamage, move the
powerswitchtoOFFanddisconnectmaincircuit
breaker, orunplugcord atwallreceptacle.
2. Shut offthewatersupply.
2-2 103

Model HCS-2,HCW-3/HCW-5/HCW-8
2-5. CLEANINGWATER 3. Remove thecontrolside endpanel.
STRAINER(Continued)
4. Remove thehex cap atthe bottomof thewater strainer.
5. Remove thescreenfrominsidethe strainerandclean.
6. Reassemble inreverseorder.
7. Turnon thewater supply andcheck forleaks.
8. Replace theendpanel.
9. Turnthe poweron at thebreaker box.
103 2-3
Step 4
Step 4
Step 5

Model HCS-2,HCW-3/HCW-5/HCW-8
2-6. WATER STRAINER 1. Removeelectricalpower suppliedtothecabinet.
(REPLACEMENT)
Toavoidelectrical shock orpropertydamage, move the
powerswitchtoOFFanddisconnectmaincircuit
breaker, orunplugcord atwallreceptacle.
2. Shut offthewatersupply.
3. Remove thecontrolsideend panel.
4. Disconnectthewatersupplytubing.
5. Remove thebrasselbow.
6. Remove thewaterstrainer.
7. Install anewwaterstrainer.
8. Reassemble inreverseorder.
9. Turnthe watersupply on andcheck forleaks.
10. Replaceend panel.
11. Turnon thepower supplyat thebreaker box.
2-7. WATERVALVE 1. Removeelectrical power suppliedtothecabinet.
Toavoidelectrical shock orpropertydamage, move the
powerswitchtoOFFanddisconnectmaincircuit
breaker, orunplugcord atwallreceptacle.
2. Shut offthewatersupply.
3. Remove thecontrolsideend panel.
2-4 103

Model HCS-2,HCW-3/HCW-5/HCW-8
2-7. WATERVALVE 4. Checkacross terminals ofthewatervalvewith anohmmeter.
(Continued) Themeter readingshouldbe 600-650,if reading isnot correct
replacethewatervalvebycontinuing with thisprocedure.
5. Removetheelectricalwiresfromthewatervalve.
6. Disconnectwaterline.
7. Remove thenutfromthebulkhead. Thisisinsidethewater pan.
Step 7
8. The watervalveassembly can nowberemoved fromthe
cabinet.
9. Remove thereducernippleand bulkheadfromthewater valve.
10. Removethe reducernipple,water strainerand elbow asone
piece.
11. Removetheremainingelbowfromthewatervalve.
12. Reassemblea newvalvein reverseorder.
13. Turn onthe water supplyand checkforleaks.
14. Replacethe end panel.
15. Turnonthe powersupply atthe breakerbox.
103 2-5
Step 9
Step 10

Model HCS-2,HCW-3/HCW-5/HCW-8
2-8. FLOATSWITCH 1. Removeelectricalpowersupplied tothecabinet.
Toavoidelectrical shock orpropertydamage, move the
powerswitchtoOFFanddisconnectmaincircuit
breaker, orunplugcord atwallreceptacle.
2. Drain thewaterpanby removing thedrainstandpipe.
3. Remove thecontrolsideend panel.
4. Cutfloatswitchwiresjustbehindswitch.
5. Frominsideendchannel,removenylonfittingbyunscrewing
fromfloatswitch.
6. Removefloatswitch.
7. Install anewfloat switchinreverseorder.Make surefloat
switchislocatedin center ofholeandsilicone washer is
positionedproperly.
Tightennut tosnugonly.Maximum torquenottoexceed3ft.
pounds.
2-6 103
Step 6

Model HCS-2,HCW-3/HCW-5/HCW-8
2-8. FLOATSWITCH 8. Stripthewire endsthat werecut, aswell asthe wire ends on
(Continued) thenewfloatswitch.Reconnectwiresusingwirenuts.
9. Replace theendpanel.
10. Turnonthe powersupply atthe breakerbox.
2-9. LIGHTSWITCH 1. Removeelectricalpower suppliedtothecabinet.
Toavoidelectrical shock orpropertydamage, move the
powerswitchtoOFFanddisconnectmaincircuit
breaker, orunplugcord atwallreceptacle.
2. Remove controlsideendpanel.
3. Removethewiresfromtheswitch.Usingatestinstrument,
checkacrosstheterminals of theswitchwiththeswitch in the
ON position,theninthe OFF position.Withtheswitchinthe
ON positionthecircuitshouldbe closed.With the switchinthe
OFFposition the circuitshould be open.If the switchchecks
defective,replacebycontinuingwiththisprocedure.
4. Remove nutfromcontrolpanelsideand remove switch.
5. Install anewswitchin reverseorder.
6. Replace theendpanel.
7. Turnon thepower supplyat thebreaker box.
103 2-7
Step 3

Model HCS-2,HCW-3/HCW-5/HCW-8
2-10. POWERSWITCH 1. Remove electricalpowersuppliedto the cabinet.
Toavoidelectrical shock orpropertydamage, move the
powerswitchtoOFFanddisconnectmaincircuit
breaker, orunplugcord atwallreceptacle.
2. Remove thecontrolsideend panel.
3. Remove theelectricalwiresfromtheswitch.Using a test
instrument,checkacrosstheterminalsoftheswitch with the
switchinthe ONposition,thenin theOFFposition.With the
switchinthe ONposition,thecircuit shouldbeclosed.Withthe
switchin the0or OFFposition, the circuitshould beopen.If
theswitchchecksdefective,replacebycontinuingwiththis
procedure.
4. Remove thenutfromthe control panelsideofswitch and
removeswitch.
5. Install anewswitchin reverseorder.
6. Replace theendpanel.
7. Turnon thepower supplyat thebreaker box.
2-8 103
Step 3

Model HCS-2,HCW-3/HCW-5/HCW-8
2-11. WATERCONTROL 1. Remove electrical powersuppliedtothe cabinet.
SWITCH
Toavoidelectrical shock orpropertydamage, move the
powerswitchtoOFFanddisconnectmaincircuit
breaker, orunplugcord atwallreceptacle.
2. Remove thecontrolsideend panel.
3. Removetheelectricalwires from theswitch. Usingatest
instrument,checkacrosstheterminalsoftheswitch with the
switchintheAUTOMATICandMANUALposition;thenin
theOFF position. Withthe switch inthe AUTOMATICor
MANUALposition,thecircuitshould beclosed. With the
switchin the0 or OFFposition, thecircuit shouldbe open. If
the switchchecks defective, replace by continuing with this
procedure.
4. Remove thenutandguard fromthecontrol panel sideofthe
switchandremovetheswitch.
5. Install anewswitchin reverseorder.
6. Replace endpanel.
7. Turnon thepower supplyat thebreaker box.
2-12. INFINITESWITCH 1. Remove electricalpowersuppliedto the cabinet.
Toavoidelectrical shock orpropertydamage, move the
powerswitchtoOFFanddisconnectmaincircuit
breaker, orunplugcord atwallreceptacle.
2. Remove thecontrolsideend panel.
103 2-9
Step 3

Model HCS-2,HCW-3/HCW-5/HCW-8
2-12. INFINITESWITCH 3. Removetheelectricalwiresfromtheswitch.
(Continued) 4. Removetheswitchknobbypullingitoff.
5. Remove thenutfromthe controlpanelsideof the switchand
removetheswitch.
6. Install anewswitchin reverseorder.
Do not connect a “hot” wire to termimal “P” on the
infinite switch, or damage to the switch will result.
7. Replace theendpanel.
8. Turnon thepower supplyat thebreaker box.
2-13. THERMOSTAT 1. Removeelectrical power suppliedtothecabinet.
Toavoidelectrical shock orpropertydamage, move the
powerswitchtoOFFanddisconnectmaincircuit
breaker, orunplugcord atwallreceptacle.
2. Remove thecontrolsideend panel.
3. Remove theelectricalwiresfromthethermostat. Usingatest
Step 3 instrument,checkacrosstheterminalsofthe thermostat.With
thethermostat in the0 orOFFposition, thecircuitshould be
open. Withthethermostat set atthemaximumsetting,the
circuitshouldbe closed. Ifthethermostat checks defective,
replaceitbycontinuingwiththisprocedure.
4. Remove thethermostatknob bylooseningthe setscrewand
pullingitoff.
2-10 305
Step 3

Model HCS-2,HCW-3/HCW-5/HCW-8
2-13. THERMOSTAT 5. Removethesensor bulb bypullingonthecapillarytube.
(Continued)
6. Removethetwomountingscrewsfromthethermostat.
7. Install anewthermostatin reverseorder.
8. Replace theendpanel.
9. Turnon thepower supplyat thebreaker box.
2-14. INDICATINGLIGHT 1. Removeelectrical powersuppliedtothecabinet.
Toavoidelectrical shock orpropertydamage, move the
powerswitchtoOFFanddisconnectmaincircuit
breaker, orunplugcord atwallreceptacle.
2. Remove thecontrolsideend panel.
103 2-11
Step 5
Step 6

Model HCS-2,HCW-3/HCW-5/HCW-8
2-14. INDICATINGLIGHT 3. Cutthelightwiresjustbehindthelighthousing.
(Continued) 4. Squeeze theplasticretainerson thelightbody and pushthe
lightthroughthecontrolpanel.
5. Installanewlightbypushingthelightthroughthecontrolpanel
untilthelightsnapssecurelyinthepanel.
6. Strip thewiresandreconnect withwirenuts.
7. Replace theendpanel.
8. Turnon thepower supplyat thebreaker box.
.
2-15. THERMOMETER 1. Remove electricalpowersuppliedto the cabinet.
Toavoidelectrical shock orpropertydamage, move the
powerswitchtoOFFanddisconnectmaincircuit
breaker, orunplugcord atwallreceptacle.
2. Remove thecontrolsideend panel.
3. Removethesensorbulbbyremovingbulbretainerandpulling
onthecapillarytube.
4. Remove thenutsholdingthemounting bracketsonthebackof
thermometerhousing.Pushthethermometerthroughthecontrol
panel.
5. Install anewthermometerin reverse order.
6. Replace theendpanel.
7. Turnon thepower at thebreaker box.
2-12 103
Step 3
Step 3
Step 4