TECHNICAL MANUAL - Henny Penny...Henny Penny Heated Merchandisers Model HMR-103 Model HMR-104 Model...

Henny PennyHeated Merchandisers

Model HMR-103Model HMR-104Model HMR-105Model HMR-106Model HMR-107

TECHNICAL MANUAL

Model HMR-103,104,105,106,107

TABLE OF CONTENTSSection PageSection 1. TROUBLESHOOTING .................................................................................................... 1-1

1-1 Introduction ........................................................................................................... 1-11-2 Safety .................................................................................................................... 1-11-3. Troubleshooting ..................................................................................................... 1-11-4. Error Codes and Warnings .................................................................................... 1-4

Section 2. MAINTENANCE ............................................................................................................. 2-12-1. Introduction ........................................................................................................... 2-12-2. Maintenance Hints ................................................................................................ 2-12-3. Front Glass Replacement ...................................................................................... 2-12-4. Radiant Heater Replacement ............................................................................... 2-32-5. Light Socket Replacement .................................................................................... 2-42-6. Water Heater Replacement .................................................................................. 2-52-7. Water Probe Replacement .................................................................................... 2-72-8. Base Heater Replacement .................................................................................... 2-102-9. Blower Motor Replacement ................................................................................. 2-112-10. Air Probe Replacement ........................................................................................ 2-122-11. Transformer Replacement .................................................................................... 2-152-12. Food Probe Receptacle Replacement .................................................................. 2-162-13. Relay Replacement ............................................................................................... 2-172-14. Cooling Fan Replacement ..................................................................................... 2-182-15. Fuse and Fuse Holder Replacement ..................................................................... 2-202-16. High Limit Replacement - Automatic Reset ......................................................... 2-212-17. High Limit Replacement - Manual Reset ............................................................. 2-222-18. Power Switch Replacement ................................................................................. 2-232-19. Contactor Replacement ........................................................................................ 2-242-20. PC Board Replacement ........................................................................................ 2-252-21. Light Bulb Replacement ....................................................................................... 2-262-21. Wiring Diagrams ................................................................................................... 2-27

106 iFM06-010 Revised 11-30-2020

Model HMR-103,104,105,106,107

203 1-1

SECTION 1. TROUBLESHOOTING

1-1. INTRODUCTION This section provides troubleshooting information in the form of aneasy to read table.

If a problem occurs during the first operation of a new unit,recheck the Installation Section of the Operator’s Manual.

Before troubleshooting, always recheck the operatingprocedure per the Operation Section of the Operator’s Manual.

1-2. SAFETY Where information is of particular importance or is safety related,the words, NOTICE, CAUTION, or WARNING are used.Their usage is described below.

SAFETY ALERT SYMBOL is used with DANGER, WARNING,or CAUTION which indicates a personal injury type hazard.

NOTICE is used to highlight especially important information.

CAUTION used without the safety alert symbol indicatesa potentially hazardous situation which, if not avoided,may result in property damage.

CAUTION used with the safety alert symbol indicates apotentially hazardous situation which, if not avoided, mayresult in minor or moderate injury.

WARNING indicates a potentially hazardous situationwhich, if not avoided, could result in death or serious injury.

1-3. TROUBLESHOOTING To isolate a malfunction, proceed as follows:

1. Clearly define the problem (or symptom) and when itoccurs.

2. Locate the problem in the troubleshooting table.

3. Review all possible causes. Then, one-at-a-time workthrough the list of corrections until the problem is solved.

Model HMR-103,104,105,106,107

1-3. TROUBLESHOOTING (Continued) PROBLEM CAUSE CORRECTION

With power switch in • Open circuit • Check to see that unit isPOWER position, unit plugged inis completelyinoperative (no power) • Check breaker or fuse at

supply box

• Check control panel fuses per Fuseand Fuse Holder Replacement Section

• Check voltage at wall receptacle

• Check POWER switch; replace if defective

• Check cord and plug for loose connections

• Control board defective • Check for 12 volt input from transformer; replace if

defective

• Transformer defective • Check input and output voltage;replace if defective

Unit will not heat • Control board not calling • Check set point reading; if unit for heat below setpoint and not calling

for heat, control board defective

• Power on, board has • Hi limit tripped; check for no display defective hi limit, or defective

blower motor

No air heat • Faulty heat relay • Check and replace

• Faulty air heater • Check and replace

• Unit not preheated • Preheat unit with pans inplace before loading product

• Faulty radiant/air heat PC board • Replace PC Board

1-2 803

Model HMR-103,104,105,106,107

1-3. TROUBLESHOOTING (Continued)

PROBLEM CAUSE CORRECTION

No radiant heat • Faulty control • Replace the appropriate PC Board; PC board each well has its own control board

• Faulty radiant heater • Replace radiant heater

No water heat • Faulty radiant/water heat • Replace PC board PC board

• Faulty water heater • Replace water heater

No lights • Light switch defective • Replace light switch

• Light relay defective • Replace relay (same as heat relay)

• Light socket shorted • Replace light socket

• Light bulb blown • Replace light bulb

Canopy glass fogging • Air blowers not circulating • Replace blower motor heated air across glass

• Water heat setting too high • Lower water heat setting

• Radiant heat setting too low • Raise radiant heat setting

Product not holding • Doors are left open • Keep doors closed except totemperature load and unload product

• Heat settings too low • Adjust heat settings

• Low or improper voltage • Using meter, compare receptacle voltage to data plate voltage

• Product held too long • Hold product for recommended time

• Product not placed correctly in unit • Place product in unit as per Operationwith Product Section of Operator’sManual

803 1-3

Model HMR-103,104,105,106,107

1-4. ERROR CODES AND The display shows the following error codes and warnings when a WARNINGS fault is detected, along with an alarm sound. Both the heat and

humidity systems shut down, except when specified otherwise.

1-4 803

DISPLAY

LO

HI

“E-4”

“E-6”

“E-41”

“E-56”

CAUSE

• Food probe or actual temperatureis below 50o F (10o C) in Calibra-tion Mode only

• Food probe temperature above500o F (260o C) or lower airtemperature 275o F (135o C), orabove

• Control board temperature above140o F (60o C)

• Air probe error; displayed if theprobe resistance falls below 930ohms or rises above 2036 ohms;the exception is on the upper heatcontrol; any high resistance ap-pears as if no food probe isplugged in

• Scrambled PC board memory

• Setpoint storage error

• Allow unit to heat-up, or remove foodfrom unit

• Check the probes and heating circuit

• Check or clean cooling fans; if “E-4”persists, replace PC board

• Check probe and connection at PCboard

• Press UP button to clear “E-41”; if“E-41” persists, replace PC board

• Press UP button to clear “E-56”, thenturn unit off and back on; if “E-56”persists, replace PC board

CORRECTION

Model HMR-103,104,105,106,107

2-1. INTRODUCTION This section provides procedures for the checkout and re-placement of the various parts used within the heated mer-chandiser. Before replacing any parts, refer to the Trouble-shooting Section. It will aid you in determining the cause ofthe malfunction.

2-2. MAINTENANCE HINTS 1. You may want to use a multimeter to check the electriccomponents.

2. When the manual refers to the circuit being closed, themultimeter should read zero unless otherwise noted.

3. When the manual refers to the circuit being open, the multi-meter reads infinity.

2-3. FRONT GLASS REPLACEMENT 1. Raise the front glass to expose the gas shocks.

2. Using a 3 mm Allen wrench, loosen the set screws onthe shock bracket armature (Figure 2-1).

Figure 2-1

3. Using a Phillips head screwdriver, remove the screwssecuring the exterior end cap and remove end cap(Figure 2-2).

203 2-1

Figure 2-2

SECTION 2. MAINTENANCE

Model HMR-103,104,105,106,107

2-3. FRONT GLASSREPLACEMENT (Continued)

4. Using a Phillips head screwdriver, remove the screwssecuring the interior end cap and remove cap(Figure 2-3).

Figure 2-35. Hold glass upright, then use the gas shock tool (part no.

56878), to release the shock from the brackets (Figure2-4). Place tool on shock as shown and squeeze handle.Be sure to hold onto glass to prevent glass from breaking.

Note location and strength (N) of shock beforeremoving.

Figure 2-4

6. Slide glass assembly off end of unit (Figure 2-5).

Figure 2-5

2-2 1202

Model HMR-103,104,105,106,107

To avoid electrical shock or property damage, movethe POWER switch to OFF and disconnect maincircuit breaker, or unplug cord at wall receptacle.

1. Remove sliding doors.

2. Using a Phillips head screwdriver, remove 3 screwsaround the heater, leaving the top right screw.

3. Using a Phillips head screwdriver, remove the 4 screwssecuring the heater housing and allow housing to hingedown (Figure 2-7).

4. Remove fourth screw from around heater and removeouter housing (Figure 2-8).

Figure 2-6

Figure 2-8

1202 2-3

2-3. FRONT GLASSREPLACEMENT (Continued)

7. Slide new glass assembly into place, aligning outside edgeof glass clamp to the outside edge of the canopy(Figure 2-6).

8. Tighten set screws on shock bracket armatures(Figure 2-1).

9. Using the gas shock tool, reinstall the gas shocks, placingthe bottom end of shock in place first.

10. Replace interior end cap, with it being completely flush withglass clamp.

11. Replace the exterior end caps. Make sure spacers arebetween the end cap and the canopy.

2-4. RADIANT HEATERREPLACEMENT

Figure 2-7

Model HMR-103,104,105,106,107

2-4 506

2-4. RADIANT HEATERREPLACEMENT (Continued)

5. Using a 3/8” socket, remove the wires from the backof the radiant heater (Figure 2-9).

Using a multimeter, or ohmmeter, check ohm rating with-out the wires connected. The Ohm ratings:208V - Hot - 84.8 ohms; Cold - 72.7 - 88.9 ohms230V - Hot - 103.7 ohms; Cold - 88.9 - 108.7 ohms240V - Hot - 221.5 ohms; Cold - 189.9 - 232.1 ohms

6. Install new radiant heater in reverse order.

When re-attatching the heater wires to the heater thebottom nut must be held in place while the top nut istightened down on the heater wires.

Figure 2-9

2-5. LIGHT SOCKET REPLACEMENT


1. Raise canopy glass and remove light bulb.

2. Using 3/8” socket, remove the 2 keps nuts securing thelight socket assembly (Figure 2-10).

3. Pull socket assembly from studs.

4. Using a Phillips head screwdriver, remove the wires fromthe socket (Figure 2-11).

Figure 2-10

Figure 2-11

Model HMR-103,104,105,106,107

1. Remove pans and pan supports from unit.

2. Using a 3/8” socket, remove the acorn nuts securing theheater cover (Figure 2-13).

3. Remove the 3 Phillips head screws securing the rear ofthe heater cover (Figure 2-14).

4. Cut the silicone seal around the rear of the cover.

Figure 2-13

Figure 2-14

203 2-5

2-5. LIGHT SOCKET REPLACEMENT(Continued)

5. Squeeze the brackets and pull socket from housing(Figure 2-12).

6. Install new socket in reverse order.

Figure 2-12

2-6. WATER HEATER REPLACEMENT

To avoid electrical shock or property damage,move the POWER switch to OFF and disconnectmain circuit breaker, or unplug cord at wallreceptacle.

Model HMR-103,104,105,106,107

2-6. WATER HEATER REPLACEMENT 5. Remove the 5 Phillips head screws securing side mount-(Continued) ing plate (Figure 2-15).

6. Remove the Phillips head screws securing the bottom,rear cover and let hinge down (Figure 2-16).

7. Cut wire ties to probe wires (Figure 2-17).

Figure 2-15

Figure 2-16

Figure 2-17

2-6 1202

Model HMR-103,104,105,106,107

Figure 2-18

Figure 2-19

803 2-7

2-6. WATER HEATER REPLACEMENT(Continued)

8. Disconnect wires from heater (Figure 2-18).

Using a multimeter, or ohmmeter, check ohm rating with-out the wires connected. The ohm ratings:208V - Hot - 108.1 ohms; Cold - 97.8 - 113.3 ohms230V - Hot - 132.2 ohms; Cold - 119.6 - 138.5 ohms

9. Pull heater cover from side mounting plate.

10. Flip heater cover to expose heater.

11. Using 5/16” socket, remove keps nuts securing theheater clips, and pull heater from heater cover(Figure 2-19).

12. Replace new heater in reverse order.

2-7. WATER PROBE REPLACEMENT

To avoid electrical shock or property damage,move the POWER switch to OFF and disconnectmain circuit breaker, or unplug cord at wall recep-tacle.

Figure 2-20


2. Using a 3/8” socket, remove the acorn nuts securingthe heater cover (Figure 2-20).

Model HMR-103,104,105,106,107

2-7. WATER PROBE REPLACEMENT 3. Remove the 3 Phillips head screws securing the rear of(Continued) the heater cover (Figure 2-21).

4. Cut the silicone seal around the rear of the cover.

5. Remove the 5 Phillips head screws securing side mount-ing plate (Figure 2-22).


Figure 2-21

Figure 2-22

Figure 2-23

2-8 1202

Model HMR-103,104,105,106,107

2-7. WATER PROBE REPLACEMENT 7. Cut wire ties to probe wires (Figure 2-24).(Continued)

\

8. Unplug probe from wiring harness (Figure 2-25).

9. Using 5/16” socket, loosen keps nut on probe clip andpull probe from unit.

10. Install new probe in reverse order.

Extend probe 1-1/2” (38 mm), from clip (Figure 2-26).

Figure 2-24

Figure 2-25

Figure 2-26

1202 2-9

Model HMR-103,104,105,106,107

2-8. BASE HEATER REPLACEMENT



2. Remove Phillips head screws from heater bracket(Figure 2-27).

3. Using a 3/8” wrench or socket, remove the acorn nutsecuring the heater brace and remove brace.


5. Pull wires from heater and pull heater from unit(Figure 2-29).

Using a multimeter, or ohm meter, check ohm ratingwithout the wires connected. The ohm ratings:208V - Hot - 66.5 ohms; Cold - 60.2 - 89.7 ohms240V - Hot - 88.6 ohms; Cold - 80.1 - 92.8 ohms

6. Install new heater in reverse order.

Figure 2-27

Figure 2-28

Figure 2-29

2-10 506

Model HMR-103,104,105,106,107

2-9. BLOWER MOTOR REPLACEMENT



2. Remove the 3 screws from the blower bracket and pullblower motor assembly from housing (Figure 2-31).

3. Using an Allen wrench, loosen the set screw securingthe fan blade to the blower motor and pull fan blade frommotor (Figure 2-32).

4. Cut wires to blower motor and pull motor from unit.

5. Strip back the cut wires, and connect new blower motorwires to these wires, using wire splicers or wire nuts.

6. Install new blower motor in reverse order.

Figure 2-30

Figure 2-31

Figure 2-32

203 2-11

Model HMR-103,104,105,106,107

2-10. AIR PROBE REPLACEMENT



2. Cut wires ties to probe wires (Figure 2-34).

3. Unplug the probe from the wire harness (Figure 2-35).

4. Using a multimeter, or ohmmeter, check across the probeterminals for the correct ohms using the RTD ResistanceChart on the following page. If the probe proves faulty,continue onto step 5. If probe is good, replace wire tieson wires.

Figure 2-33

Figure 2-34

Figure 2-35

2-12 203

Model HMR-103,104,105,106,107

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CO

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11.6

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45.5

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412

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55

12.7

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49.8

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613

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1052

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54.1

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58.4

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62.8

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216

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18.3

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71.4

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19.4

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75.7

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84.4

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88.7

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423

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76

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72.5

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424

311

7 .22

1450

.13

244

117 .

7814

52.2

324

511

8 .33

1454

.32

246

118 .

8914

56.4

224

711

9 .44

1458

.51

248

120 .

0014

60.6

124

912

0 .56

1462

.70

250

121 .

1114

64.7

9

701 2-13

Model HMR-103,104,105,106,107

2-10. AIR PROBE REPLACEMENT 5. Using a 3/4” wrench, loosen probe strain relief and pull (Continued) the probe from the unit (Figure 2-36).

6. Install new probe in reverse order, extending the probe1/8” into cabinet (Figure 2-37).

Figure 2-37

Some probes are held into place by a probe bracket in-stead of a strain relief. Press on the edge of the bracketto relax the tension on the probe and then pull probe fromunit. Extend the new probe about 1/4” into cabinet(Figure 2-38).

Figure 2-36

Figure 2-38

2-14 1202

Model HMR-103,104,105,106,107

2-11. TRANSFORMER REPLACEMENT


1. Remove the Phillips head screws securing the top, rearcover, and let cover hinge down (Figure 2-39).

Figure 2-39

2. Label, and then pull the wires from the transformer(Figure 2-40).

3. Remove the Phillips head screws securing the transformerand pull transformer from unit (Figure 2-41).

4. Install new transformer in reverse order.

Figure 2-40

Figure 2-41

203 2-15

Model HMR-103,104,105,106,107

2-12. FOOD PROBE RECEPTACLE REPLACEMENT



2. Cut wire ties securing receptacle wires and disconnectreceptacle from wire harness.

3. Using 3/8” socket, remove nuts securing bracket andpull bracket and receptacle from unit (Figure 2-43).

4. Remove the Phillips head screw securing the receptacleto the bracket and remove receptacle from bracket(Figure 2-44).

5. Install new receptacle in reverse order.

Figure 2-42

Figure 2-43

Figure 2-44

2-16 1202

Model HMR-103,104,105,106,107

2-13. RELAY REPLACEMENT



2. Label wires, and then loosen the Phillips head screwssecuring the wires to the relay and pull wires from relay(Figure 2-46).

3. Remove the Phillips head screws securing the relay tothe unit, and then pull relay from unit (Figure 2-47).

4. Install new relay in reverse order.

Figure 2-45

Figure 2-46

Figure 2-47

203 2-17

Model HMR-103,104,105,106,107

2-14. COOLING FAN REPLACEMENT



For bracket mounted fan instructions, see next page.

2. Using 5/16” socket, remove nuts securing the fan(Figure 2-49).

3. Cut the cooling fan wires and remove the cooling fan fromthe unit (Figure 2-50).

4. Strip back the cut wires, and connect new blower motorwires to these wires, using wire splicers or wire nuts.

5. Install new cooling fan in reverse order, making sure theair blows into the cabinet.

Figure 2-48

Figure 2-49

Figure 2-50

2-18 203

Model HMR-103,104,105,106,107

2-14. COOLING FAN REPLACEMENT (Continued)

6. Remove Phillips head screws securing the fan bracket(Figure 2-51).

7. Remove screws and nuts securing the fan to the bracket(Figure 2-52).

8. Cut wires to cooling fan and remove the fan from the unit(Figure 2-53).

9. Strip back the cut wires, and connect new cooling fanwires to these wires, using wire splicers or wire nuts.

10. Install new cooling fan in reverse order, making sure theair blows towards the outside of the unit.

Figure 2-51

Figure 2-52

Figue 2-53

1202 2-19

Model HMR-103,104,105,106,107

2-15. FUSE AND FUSE HOLDER REPLACEMENT


Fuse Replacement1. Unscrew fuse holder cap counterclockwise to access fuse

(Figure 2-54).

To check fuse, use a multimeter, or continuity tester, and putleads on each end of fuse. If meter shows circuit is closed,fuse is good. Replace fuse with a 15 amp fuse (20 ampfuse-CE), if meter shows circuit is open.

Fuse Holder Replacement


2. Pull wires from fuse holder terminals.

3. Using 5/16” socket remove nuts securing fuse holder andpull holder from unit (Figure 2-56).

4. Install new fuse holder in reverse order.

Figure 2-54

Figure 2-55

Figure 2-56

2-20 203

Model HMR-103,104,105,106,107

2-16. HIGH LIMIT REPLACEMENT - AUTOMATIC RESET



2. Pull wires from high limit (Figure 2-58).

To check high, use a multimeter or continuity tester, and putleads on each terminal of high limit. With the unit at roomtemperature, the meter shows a closed circuit if high limit isgood. Replace high limit if meter shows circuit is open.

3. Using 1/4” socket, remove nuts securing high limit, pull itfrom the unit (Figure 2-59).

4. Replace new high limit in reverse order.

Figure 2-57

Figure 2-58

Figure 2-59

203 2-21

Model HMR-103,104,105,106,107

2-17. HIGH LIMIT REPLACEMENT - MANUAL RESET



2. Pull wires from high limit (Figure 2-61).

To check high limit, allow unit to cool, then press the resetbutton to make sure high limit is reset. Use a multimeter, orcontinuity tester, and put leads on each terminal of high limit.If the meter shows circuit is closed, the high limit is good.Replace high limit if meter shows circuit is open.

3. Using 1/4” socket, remove nuts securing the high limit,and pull high limit from unit (Figure 2-62).

4. Install new high limit in reverse order.

Figure 2-60

Figure 2-61

Figure 2-62

2-22 203

Model HMR-103,104,105,106,107

2-18. POWER SWITCH REPLACEMENT


1A. For switches on bottom rear cover, remove the Phillipshead screws securing the bottom rear cover and let hingedown (Figure 2-63).

1B. For switches on top rear cover, remove the Phillips headscrews securing the top rear cover and let hinge down(Figure 2-64).

2. Label wires and then pull them from the switch(Figure 2-65).

3. Press tabs together and pull switch from front of panel(Figure 2-66).

4. Install new switch in reverse order.

Figure 2-63

Figure 2-64

Figure 2-66

Figure 2-65

203 2-23

Model HMR-103,104,105,106,107

2-19. CONTACTOR REPLACEMENT



2. Using 3/8” socket, remove the nuts securing the contactorand pull contactor off of studs (Figure 2-68).

3. Label wires and then remove the Phillips head screwssecuring the wires (Figure 2-69).

4. Install new contactor in reverse order.

Figure 2-67

Figure 2-68

Figure 2-69

2-24 203

Model HMR-103,104,105,106,107

2-20. PC BOARD REPLACEMENT



2. Remove the nuts securing the housing and pull housingfrom unit (Figure 2-71).

3. Disconnect connectors to the PC board (Figure 2-72).

4. Using 5/16” socket, remove the nuts securing the PCboard and pull the board from the unit (Figure 2-73).

5. Install new PC board in reverse order.

Figure 2-70

Figure 2-71

Figure 2-72

Figure 2-73203 2-25

Model HMR-103,104,105,106,107

2-21. LIGHT BULB REPLACEMENT


Light bulbs and glass may be hot. Severe burns couldresult.

1. Raise the glass canopy and ensure that the gas shockssupport its weight before proceeding.

Do Not attempt to access the bulb from the operator’sside of the unit. The installer cannot easily see the bulband socket or the adjacent radiant heaters, increasing thepotential shock or burn hazard.

2. Carefully remove the old bulb and discard. Figure 2-74.

3. Visually inspect socket to ensure there is no debris or damagethat may impede bulb installation. Figure 2-75.

4. Install the replacement bulb. Tighten using a gentle pressure.

To help prevent a short bulb life:

• Do not over-tighten the bulb. Over-tightening willdamage the contact end of the bulb and compress thecontact tab in the socket

• Do not install the bulb with the power on. During normaloperation, the socket is exposed to various food relatedagents, such as moisture and grease. When installing anew bulb with the power on, the spark that occurs whenthe bulb contact touches the socket, places a deposit onthe bottom of the bulb. This deposit results in a higheramp draw and shorter bulb life.

Figure 2-74

Figure 2-75

2-26 1104

Model HMR-103,104,105,106,107

603 2-27

2-21. WIRING DIAGRAMS

Model HMR-103,104,105,106,107

2-28 701

2-21. WIRING DIAGRAMS (Continued)

Model HMR-103,104,105,106,107

701 2-29

2-21. WIRING DIAGRAMS (Continued)

Model HMR-103,104,105,106,107

2-30 506

Model HMR-103,104,105,106,107

1104 2-31

Model HMR-103,104,105,106,107

2-32 1104

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