Henny Penny BCM-110 User manual

TECHNICAL MANUAL
Henny Penny
Blast Chiller/Freezer
Models BCF-24/65/110
BCM-110

Model BCF-24/65/110, BCM-110
TABLEOFCONTENTS
Section Page
Section 1. TROUBLESHOOTING...........................................................................................................1-1
1-1. Introduction ..................................................................................................................1-1
1-2. Safety...........................................................................................................................1-1
1-3. Troubleshooting ............................................................................................................1-1
1-4. Alarm Messages..........................................................................................................1-5
Section 2. MAINTENANCE ....................................................................................................................2-1
2-1. Introduction ..................................................................................................................2-1
2-2. Maintenance Hints .......................................................................................................2-1
2-3. Compressor, Drier, Expansion Valve, Sight Glass, and Condenser Fan.......................2-1
2-4. Display Board andAuxiliary Display Board ................................................................2-1
2-5. Control Board ..............................................................................................................2-2
2-6. Buzzer ..........................................................................................................................2-3
2-7. Contactor .....................................................................................................................2-3
2-8. Door Frame Heater .....................................................................................................2-4
2-9. Evaporator Fan ............................................................................................................2-4
2-10. Air Probe and Evaporator Probe .................................................................................2-5
2-11. Frigiprobe .....................................................................................................................2-5
2-12. Fuse and Fuse Holder ..................................................................................................2-6
2-13. Condensation Evaporator.............................................................................................2-6
2-14. Door Seal .....................................................................................................................2-7
2-15. Run Capacitor ..............................................................................................................2-8
2-16. Start Capacitor and Start Relay ...................................................................................2-8
2-17. Preventive Maintenance ..............................................................................................2-9
Wiring Diagram ......................................................................................................................2-10
Refrigeration Diagram............................................................................................................2-11
Electrical/Refrigeration Diagram............................................................................................2-13
Wiring Information of PC Board ............................................................................................2-14
Section 3. PARTS INFORMATION .........................................................................................................3-1
3-1. Introduction ..................................................................................................................3-1
3-2. Genuine Parts ..............................................................................................................3-1
3-3. How to Order Parts .....................................................................................................3-1
3-4. Prices ...........................................................................................................................3-1
3-5. Delivery .......................................................................................................................3-1
3-6. Warranty ............................................................................................................3-1
3-7. RecommendedSparePartsforDistributors .........................................................3-1
206 i
FM06-023
Revised08-03-06

Model BCF-24/65/110, BCM-110
Thissectionprovidestroubleshootinginformationintheform
ofan easy-to-readtable.
Ifaproblemoccursduringthefirst operation of a cabinet,
rechecktheinstallationpertheInstallationSectionoftheOperator’s
Manual.
Beforetroubleshooting,alwaysrechecktheoperationproceduresin
theOperator’s Manual.
603 1-1
1-1. INTRODUCTION
1-3. TROUBLESHOOTING Toisolateamalfunction,proceedasfollows:
1. Clearly define the problem or symptom and when it occurs.
2. Locate the problem inthetroubleshootingtable.
3. Review all possible causes. Then, oneatatimeworkthrough
thelistofcorrectionsuntilproblem issolved.
Ifmaintenanceprocedures arenotfollowedcorrectly,
injuriesand/orpropertydamagecouldresult.
1-2. SAFETY Whereinformationisofparticular importanceorissafety
related, the words NOTICE, CAUTION, or WARNING are
used.Theirusageisdescribedbelow.
SAFETYALERTSYMBOLis usedwithDANGER,
WARNING, or CAUTION whichindicatesa personal
injurytypehazard.
NOTICEisusedtohighlightespeciallyimportant
information.
CAUTION used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided,
may result in property damage.
CAUTION used with the safety alert symbol indicates a
potentially hazardous situation which, if not avoided,
may result in minor or moderate injury.
WARNINGindicates apotentially hazardoussituation
which,if notavoided, couldresult indeath orserious
injury.
SECTION1.TROUBLESHOOTING

Model BCF-24/65/110, BCM-110
1-3. TROUBLESHOOTING
(Continued)
Problem Cause Correction
Theevaporatoris iced-up Faultyde-icingheater Replacede-icingheater
afteraDe-icingCycle Evaporatortemperatureatend Increasethe setting of step8,in
ofDe-icingCycletoolow ProgrammingSectionof
Operator’sManual
MaximumtimeofDe-icingCycle Increasethesettingofstep7,in
tooshort ProgrammingSectionof
Operator’sManual
Too much wateron evaporator Theunithasbeenshutdownwithout StartaDe-icingCycle
fins a De-icingCycle
Slowto decrease Compressornotworkingproperly Check compressor and re-
intemperature(declinein placeifnecessary
performance) Evaporatorfannotworkingproperly Checkthefanandreplaceif
necessary
Temperatureofroomtoohigh Ventilatetheroom
Notenoughclearancearoundunit Relocatetheunit; seeLocation
Section of the Operator’s
Manual
1-2 603

Model BCF-24/65/110, BCM-110
1-3. TROUBLESHOOTING
(Continued)
Problem Cause Correction
Slowto decrease Condenserobstructedbydirt Cleanthecondenser
intemperature(declinein
performance) Evaporatoricedup PerformaDe-icingCycle
Refrigeratingproblem Checkrefrigerationcircuitand
components
Displaytemperaturedoes InFrigiprobeMode,thedisplay Normal
notmatchtheactualinletair shows the product temperature
temperature(Noalarm) Intimermode,or hold mode, Ohm out the probe and check
theprobemaybeshowingthe thereadingwiththetablelocated
wrongtemperature inthissection; change the probe
ifitisoutoftolerance
Greencompressorindicator Compressorandcondenserfan
lightonandthecompressor donotwork:
notworking,orworking -Faultycontactor Checkcontactorandchangeif
sometimes necessary
-Faultycontrol board relay-no Replace controlboard
voltageacrossterminals 10-11
Compressorworks, but condenser
fandoesnot:
-Faultycondenserfan Replacefan
Compressorandcondenser fan
worktogether:
-Faultyprotectioncomponent Checkitemsandreplaceif
for the compressor(overload necessary
protector, potential relay,start
and run capacitor)
-Faultyoverload protector of Check fanandreplace if
condenser fan necessary
603 1-3

Model BCF-24/65/110, BCM-110
1-3. TROUBLESHOOTING
(Continued)
Problem Cause Correction
Greencompressorindicator Voltageacrossterminals10-11
lightoffandcompressor of control board:
isworking - Control board relay bad Replacecontrolboard
Novoltageacross terminals 10-11
ofcontrolboard:
-Faultycontactor Replacecontactor
Greenfanindicatorlight Voltageacrossterminals8-9of
onandfan(s)notworking controlboard.
- Fan or capacitor bad Replacefanorits capacitor
-Fanthermo-switchtripped Allow the fan motor tocoolto
seeif the fancomes back on;
ifthe fan doesnot come back
on, oritkeepstripping,re-
placethefan
Novoltageacross terminals 8-9
ofcontrolboard:
-Faultycontrolboard relay Replace control board
Allindicatorlightsoffand Checkelectricalsupply Plugunitintoreceptacle,or
ON/OFFswitchwillnot resetwallcircuitbreaker
operate Fuseofcontrol board blown Change thefuse
Novoltagefromthecontrol Changethecontrolboard
boardtransformer
Connectorbetweenthecontrol Checktheconnection
boardand display board not
connectedproperly
Badwireintheconnector between Replace the connector
thecontrolboardanddisplay
board
1-4 603

Model BCF-24/65/110, BCM-110
1-4. ALARM MESSAGES Intheeventofa systemfailure,thedigitaldisplaywillshowan
alarmmessage. Thesemessages are coded;“AL-1”,“AL-2”,
“AL-3”,“AL-5”, and “AL-6.” When analarm occurs, thered
alarmLEDwillilluminateandabuzzer(optional)willsound. Press
theALARMbuttontostopthebuzzer.
Theunit can operate onauto back-up ifan alarm soundsfora
faultyprobe. Mustselect theTimer Mode,and enter a time.
Display Cause Correction
“AL-1” Faultyairtemperature Replacetheprobe; unit can operateon auto
probe back-upuntilanewprobeisinstalled
“AL-2” Faultyevaporatorprobe Replace the probe; thede-icing cycle can operate at
50%ofthesettinginstep7oftheProgrammingSection
“AL-3” FaultyFrigiprobe Replacetheprobe; theFrigiprobeMode will not
operate,buttheunitwilloperateintheTimerMode
“AL-5” Temperaturetoolow Faultycontrolboard - replacecontrol board;
intheholdmode faultycontactor-replacecontactor
“AL-6” Temperaturetoohighin Faultycontrol board -replace control board;
theholdmode door opened too much - make sure door stays
closedasmuchas possible
603 1-5

Model BCF-24/65/110, BCM-110
1-6 603

Model BCF-24/65/110, BCM-110
SECTION2. MAINTENANCE
2-1. INTRODUCTION Thissectionprovidesprocedures for the checkoutandreplacement
ofthevariouspartsusedwithintheblastchiller/freezer. Before
replacinganyparts,refertotheTroubleshootingSection. It
willaidyouindeterminingthecauseofthemalfunction.
2-2. MAINTENANCE HINTS 1. Youmaywanttouseamultimetertochecktheelectric
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 the circuit being open, the multi-
meterreadsinfinity.
2-3. COMPRESSOR, DRIER, Thesepartsinvolvemanipulatingtherefrigerantinthesystem.
EXPANSION VALVE, Anyremovaloradjustmentsto these parts mustbehandledby a
SIGHT GLASS,AND certifiedrefrigerationexpert.
CONDENSER FAN
2-4. DISPLAYBOARDAND 1. Remove the electricalpowertotheunit.
AUXILIARYDISPLAY
BOARD
Toavoid electricalshock orpropertydamage, movethe
powerswitchtoOFFand disconnectmaincircuitbreaker,
orunplugcord atwallreceptacle.
2. Using a Phillips head screwdriver, remove the two screws
securingthefrontpanel,andlowerthepanel.
3. Pull the connector from the corner of the display board.
4. Using a flathead screwdriver, remove the screws securing
the bracket to the panel, and pull the bracket from the panel.
5. Using a flathead screwdriver, push in on the clips on the
plastic studs and pull the studs through the bracket. Remove
the display board from the bracket.
6. Install the new board in reverse order.
603 2-1

Model BCF-24/65/110, BCM-110
2-5. CONTROLBOARD 1. Remove the electrical power to the unit.
Toavoid electricalshock orpropertydamage, movethe
powerswitchtoOFFand disconnectmaincircuitbreaker,
orunplugcord atwallreceptacle.
2. Using a Phillips head screwdriver, remove the two screws
securingthefrontpanel,andlowerthepanel.
3. Remove the two bolts (under unit) securing the controlbox.
4. Pull the boxfromthefrontoftheunit.
5. Remove the four screwssecuringthecontrol box top and
pullthetopfromthebox.
6. Pull the connectors from thecontrolboard.
7. Label and pull thewiresfromthecontrolboard.
8. Using a flathead screwdriver, push in on the clips on the
plasticstudsandpullthestuds through the bracket. Remove
thecontrolboard from thebox.
9. Install the newboardinreverse order.
2-2 603

Model BCF-24/65/110, BCM-110
2-6. BUZZER 1. Remove the electrical power to the unit.
Toavoid electricalshock orpropertydamage, movethe
powerswitchtoOFFand disconnectmaincircuitbreaker,
orunplugcord atwallreceptacle.
2. Using a Phillips head screwdriver, remove the two screws
securing the front panel, and lower the panel.
3. Remove the two bolts (under unit) securing the control box.
4. Pull the box from the front of the unit.
5. Remove the four screwssecuringthecontrol box top and
pullthetopfromthebox.
6. Label and remove the wires to the buzzer.
7. Remove the two screws securing the buzzer to the bracket
and remove the buzzer from the bracket.
8. Install new buzzer in reverse order.
2-7. CONTACTOR 1. Removetheelectricalpowertotheunit.
Toavoid electricalshock orpropertydamage, movethe
powerswitchtoOFFand disconnectmaincircuitbreaker,
orunplugcord atwallreceptacle.
2. Follow steps 2through5 in the ControlBoardSection.
3. Using a flathead screwdriver, remove the two screws
securing the bracket to the box, and remove the bracket.
4. Label and remove the wires from the contactor.
5. Slide the contactor off the retainer.
6. Install new contactor in reverse order.
603 2-3

Model BCF-24/65/110, BCM-110
2-8. DOOR FRAME HEATER 1. Removetheelectricalpowertotheunit.
Toavoid electricalshock orpropertydamage, movethe
powerswitchtoOFFand disconnectmaincircuitbreaker,
orunplugcord atwallreceptacle.
2. Remove the door to the unit by removing the screws in the
lower hinge of the door.
3. Remove the control box from the unit, following steps 2
through5intheControlBoardSection.
3. Remove the plastic tabs that secures the decorator covers
around the door opening, and remove the covers.
4. Peel the heateroutof the groove anddisconnectthe wires
(insidecontrolbox)totheelement,andremovetheelement
fromtheunit.
5. Install new heater in reverse order and press the plastic tabs
inplaceto secure the decoratorcovers (tabs included withnew
heater).
2-9. EVAPORATORFAN 1. Removetheelectricalpowertotheunit.
Toavoid electricalshock orpropertydamage, movethe
powerswitchtoOFFanddisconnect maincircuitbreaker,
orunplugcord atwallreceptacle.
2. Using a Phillips head screwdriver, remove the two screws
securingthefanshroud,andpulloutontheshroud.
3. Using a Phillips head screwdriver, remove the three screws
securingthefanguard,andremovetheguard.
4. Remove the controlboxfromtheunit,followingsteps2
through5intheControlBoardSection.
5. Disconnect the wires (inside control box) to the fan.
6. Remove the threescrewssecuringthefan to the evaporator
door,andpullthefanfromtheunit.
7. Install new fan in reverse order.
2-4 205

Model BCF-24/65/110, BCM-110
2-10. AIR PROBEAND 1. Removetheelectricalpowertotheunit.
EVAPORATOR PROBE
Toavoid electricalshock orpropertydamage, movethe
powerswitchtoOFFand disconnectmaincircuitbreaker,
orunplugcord atwallreceptacle.
2. Using a Phillips head screwdriver, remove the two screws
securingtheevaporator door,andpulloutonthe door.
3. Remove the appropriate probe fromthe bracket. (See photo
atleft).
4. Remove the controlboxfromtheunit,followingsteps2
through5intheControlBoardSection.
5. Find the appropriate wires to the PC board and remove the
wires from the board.
6. Pull the probe wire through the wiring harness.
7. Install new probeinreverseorder.
2-11. FRIGIPROBE 1. Removetheelectricalpowertotheunit.
Toavoid electricalshock orpropertydamage, movethe
powerswitchtoOFFand disconnectmaincircuitbreaker,
orunplugcord atwallreceptacle.
2. Using a Phillips head screwdriver, remove the two screws
securingtheevaporator door,andpulloutonthe door.
3. Remove the controlboxfromtheunit,followingsteps2
through5intheControlBoardSection.
4. Find the appropriate wires to the PC board and remove the
wires from the board.
5. Pulltheprobewirethrough thewiringharness.
6. Install new probe in reverse order.
603 2-5
Air Probe Evaporator
Probe
Frigiprobe

Model BCF-24/65/110, BCM-110
2-12. FUSEAND FUSE Ifthe unit hasno power, thefuse may be blown. Toaccessthe
HOLDER fuse:
1. Remove the electrical power to the unit.
Toavoid electricalshock orpropertydamage, movethe
powerswitchtoOFFand disconnectmaincircuitbreaker,
orunplugcord atwallreceptacle.
2. Remove the two screws securing the front panel and pull
down the panel.
3. Unscrew the fuse cap and pull the 10 amp fuse from the
holder.
To check and replace the fuse holder:
1. Remove the two screws securing the front panel and pull
down the panel.
2. Remove the two bolts securing the control box and pull the
controlboxfromthe unit. (See Control BoardSection.)
3. Removethefourscrews securing box top andremovethe top.
4. Remove the wires from the fuse holder and check for conti-
nuityacrosstheterminals. Thecircuitshouldshowclosed.
Ifopen,replacefuseholder.
5. Reinstall the control box and front panel, and unit is now
ready for use.
2-13. CONDENSATION 1. Removeelectricalpowertounit and allow evaporator tocool.
EVAPORATOR
Toavoid electricalshock orpropertydamage, movethe
powerswitchtoOFFand disconnectmaincircuitbreaker,
orunplugcord atwallreceptacle.
Also, if evaporatoris functional,it will bevery hot! Allow
evaporatortocoolbeforeremoving, orburns couldresult.
2-6 603
Fuse Holder

Model BCF-24/65/110, BCM-110
2-13. CONDENSATION 2. Bendoutthe clips securing therodent cover on theback of
EVAPORATOR (Continued) theunit,andpullthecoverdown.
3. Disconnect the wirestotheevaporator.
4. Pull up onthebottomof the evaporator todisengagethe
evaporatorfrom the bracket. Theevaporator is snappedinto
place. Nohardwareis securing it.
5. Replace evaporator inreverse order.
2-14. DOOR SEAL 1. Open door andpull out on acorner of thesealuntil seal
clears the retainer.
2. Continue around the door,pulling the seal from the door.
3. Installnewseal,startingwith thefourcornersfirst.
603 2-7

Model BCF-24/65/110, BCM-110
2-15. RUN CAPACITOR 1. Remove the electrical power totheunit.
Toavoid electricalshock orpropertydamage, movethe
powerswitchtoOFFand disconnectmaincircuitbreaker,
orunplugcord atwallreceptacle.
2. Remove the two screws securing the front panel and pull
down the panel.
3. Bend out the clips securing the rodent cover on the back of
theunit,andpullthecoverdown.
4. Using a Phillips head screwdriver, remove the two screws
securing the cover of the junction box, and remove the cover.
5. Disconnect the wires from the relay to the capacitor.
6. Remove the capacitor from the unit, from the front.
7. Install new capacitor in reverse order.
2-16. STARTCAPACITORAND 1. Removetheelectricalpowertotheunit.
STARTRELAY
Toavoid electricalshock orpropertydamage, movethe
powerswitchtoOFFand disconnectmaincircuitbreaker,
orunplugcord atwallreceptacle.
2. Bend out theclipssecuring the rodentcoveron the backof
theunit,andpullthecoverdown.
3. Using a Phillips head screwdriver, remove the two screws
securingthecoverofthejunction box, and remove the cover.
(See section 2-12 above).
4. Disconnect the wirestoeitherthe relay or thecapacitor, and
removecomponentfromthe unit.
5. Install new component in reverse order.
2-8 603
Run Capacitor
Start Relay Start Capacitor

Model BCF-24/65/110, BCM-110
2-17. PREVENTIVEMAINTENANCE Asinallfoodequipment,the HennyPennyBlast
Chiller/Freezerdoesrequirecare and proper mainte-
nance. Thetable below provides asummary of sched-
uledmaintenance.
Procedure Frequency
Cleanallsurfaceswith a soft cloth,soapandwater; Daily
donot use abrasives
De-icethe evaporator Daily
Cleanthecondenserofdust and obstructions Monthly
603 2-9

Model BCF-24/65/110, BCM-110
Wiring Diagrams BCF/BCM-110
2-10 603