SERVICE MANUAL OXE-100

Transcription

1 KFC Velocity Series Open Fryer SERVICE MANUAL OXE-100 FM06-070B

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3 Table of Contents Safety and Compliance... ix Chapter 1 Overview Technical Support Dimensions and Clearance Operating Specifications Data Plate Location...2 Chapter 2 Unpacking and Installation Unpacking the Appliance Unloading the Appliance Installing Counterweights Finish Unpacking the Appliance Selecting The Location Leveling The Fryer Ventilation of the Fryer Electrical Requirements International Electrical Requirements...7 Chapter 3 Initial Startup Loading Setpoints Drain Pan Assembly Initial Oil Fill Purge the Oil Lines Manually Fill the Vat Bulk Fill the Vat Fill the Fresh Oil Tank...13 Chapter 4 Operation Operating Components Controls and Indicators Action Buttons Mode Overview Main Menu Menu Structure Display Options Title Option Next Option Items Option...20 Chapter 5 Oil Maintenance W.A.S.S.H Boil-Over Prevention Filtering Filter Menus Quick Filter Daily Filter Polish...25 Contents i

4 Contents Chapter 6 Maintenance Regular Maintenance Schedule Wipe Mode General Cleaning - Daily Daily Filter Wipe Down the Unit Clean the Fresh Oil Tank (ATO) Clean the Drain Pan Clean the Castor Wheels - Weekly Cleaning Nylatron Filler Slides - Monthly Oil Disposal Dispose Menu Overview Manual Oil Disposal Access the Dispose Menu Drain the Oil Purge the Fittings Wipe Out the VAT Fill the Vat with Oil Rear Bulk Oil Disposal Access the Dispose Menu Drain the Oil Purge the Fittings Wipe Out the Vat Rear Disposal of the Oil - Only Fill the Vat Manually Fill the Vat from Bulk Front Bulk Oil Disposal Access the Dispose Menu Front Disposal Reminder - Connect the Hose Drain the Oil Purge the Fittings Wipe Out the Vat Front Disposal of the Oil - Only Fill the Vat Manually Fill the Vat from Bulk Clean-Out Mode Setting the Clean-Out Mode Type Clean-Out Menu Overview Access Clean-Out Mode Perform the Clean-Out Preparation Perform the Cold-Soak Clean-Out Perform the Heated Clean-Out Drain the Water Rinse the Vat With Clean Water Purge the Oil Lines Wipe the Vat Exit Confirmation...43 Chapter 7 Semi-annual and Annual Inspections Inspect Castors and Frame Inspect Counterweight Cables Inspect and Lubricate the Carriage Wheels Oil Migration...48 ii

5 7.5 Inspect Fry Pot for Leaking Temperature and Level Probe Inspection Inspect the Power Cable Electrical Requirements International Requirements High Limit and Module Inspection Measuring Amp Draw Drain Pan Component Inspection Testing the Drain Valve Bulk Dispose Test Heating Element Spreader Bars Tightening and Inspection Oil Return Diverters and Pressure Outlet Inspection Inspect for Plumbing Leaks in the Filtration System Inspect Cam Slide Fillers Replacement Maintenance Parts Ordering Parts Parts List...64 Chapter 8 Programming Program Menu Product Programming Menu Product Programming Mode Copy Menu Items Info Mode Menu Overview Special Programming Filter Control Tech Mode Menu...91 Chapter 9 Troubleshooting Troubleshooting Guide Error Codes...97 Chapter 10 Software Updates Software Updates Control Board Updates USB Port Overview SanDisk USB Flash Drive Version Updates Access the Extranet Locate and Download the Latest Version of Software Loading the Software Download a Report Chapter 11 Repair and Replacement Procedures Maintenance Hints Control Board Replacement Power Switch Replacement USB Port Replacement Nylatron Filler-Strip Replacement Inspect the Nylatron Filler Strip Kit Remove the Counterweights and Secure Carriage Assembly Remove the Tilt Stop Remove the Lid Assembly Remove the Front Shroud Contents iii

6 Contents Remove the Nylatron Filler Strip Channel Install the New Nylatron Filler Strip Install the Lid Test the Nylatron Strips Install the Tilt Stop Install the Top and Rear Access Panels High Limit Thermocouples Replacement High Limit Module Replacement Primary Contactor Replacement Heat Contactor Replacement AIF Multi-Tab Transformer Replacement Control Transformer Replacement Pump Motor Replacement Pump Motor Seal Replacement Pump Motor Roller Replacement Flex Tube Replacement Lid Cable Replacement Label Replacement Chapter 12 Zigbee Radio Overview Online Projection System (OPS) and Quality and Production Management (QPM) What is OPS/QPM Data Tracking Communication Architecture Digi ZigBee Radio Digi Radio ZigBee Protocol Mesh Network Practical Application Installation Install the Hardware Configure the OPS/QPM Settings Overview Enable OPS/QPM Verify Communication Cook ID Code Verifying the Cook ID Code ZigBee Identify Response Identify Overview Configuring the Identify Response Troubleshooting Overview Digi ZigBee Radio Basics Network Connectivity Joining a Network Data Communication Verify Power Communication Cables Check the Wires Check Data Communication Join or Re-Join the Network iv

7 ZigBee Radio Info Display Access the Display JOIN Screen CHANNEL Screen PAN ID Screen RADIO SHORT ID Screen Reset / Unjoin Command Modbus Packet Statistics Modbus Character RX/TX Statistics Chapter 13 Replaceable Parts Parts Introduction Genuine Parts When Ordering Parts Prices Delivery Warranty Recommended Spare Parts For Distributors Chapter 14 Wiring and Plumbing Diagrams V 3PH 3+G 24V Controls V 3PH 3+G 24V Controls V 3PH 3+G 24V Controls Oil Line Connections for Bulk Disposal Oil Line Connections for Non-Bulk Disposal Chapter 15 Annual and Semi-annual Inspection Checklist Form Required Tools Required Parts vcontents

8 List of Tables Table 1-1 Dimensions and Clearance...1 Table 1-2 Operation Specifications...2 Table 6-1 Regular Maintenance Schedule...27 Table 7-1 Replacement Maintenance Parts...64 Table 8-1 Info Mode Menu Function...70 Table 8-2 Special Program Menu Function...74 Table 8-3 Filter Settings...77 Table 8-4 Tech Mode Menu Function...91 Table 9-1 Troubleshooting Guide...97 Table 9-2 Error Codes...98 Table 13-1 Flex Lines Table 13-2 Flex Line Table 15-1 Annual (12 month) Inspection Checklist Table 15-2 Semi-annual (6 month) Inspection Checklist List of Figures Contents Figure 4-1 KFC...15 Figure 4-2 KFC...17 Figure 11-1 Pump Seal Kit Placement Figure 11-2 Pump Rollers Figure 12-1 Connecting Wires to Terminal Block Figure 12-2 Sliding Radio Module on to Studs Figure 12-3 Attaching Connector to Radio Figure 12-4 Securing Radio to Control Figure 12-5 Connecting 9-Pin Connector Figure 12-6 Gather Wires in Wire Tie Figure 12-7 OP Decal Location Figure 12-8 Menu & Info Button Locations Figure 12-9 Second Set of Main Menu Options Figure Programming Menus Figure SP-4 OPS/QPM Enabled Figure SP-4 OPS/QPM Enabled Yes Display Figure Join Status Display Figure Channel Status Display Figure Pan ID Display Figure Radio Short ID Display Figure Reset/Unjoin Command Display Figure Number Buttons Figure Display Figure Unique Product Number Display Figure ZigBee ID Display vi

9 Figure Screen Figure Screen Figure Screen Figure Screen Figure Screen Figure Screen Figure Screen Figure 13-1 Components Figure 13-2 Drain Pan Assembly Figure 13-3 Heating Elements Figure 13-4 Thermocouple, Heat Contactor & Control Transformer Figure 13-5 Left Side Vat Figure 13-6 Bottom Of Fryer Figure 13-7 Front Top View Figure 13-8 Pump and Valve Contents vii

10 Contents viii

11 Safety and Compliance Henny Penny fryers have many safety features incorporated. However, the only way to ensure safe operation is to fully understand the proper installation, operation, and maintenance procedures. The instructions in this manual have been prepared to aid you in learning the proper procedures. Where information is of particular importance or is safety related, the words DANGER, WARNING, CAUTION, or NOTICE are used. Their usage is described as follows: DANGER! indicates hazardous situation which, if not avoided, will result in death or serious injury. DANGER! WARNING! indicates hazardous situation which, if not avoided, could result in death or serious injury. WARNING! CAUTION! indicates hazardous situation which, if not avoided, could result in moderate or minor injury. CAUTION! NOTICE NOTICE is used for information considered important regarding property damage. Preface ix

12 These are the original version controlled Henny Penny instructions for Velocity Open Electric (OXE) model 100 (OXE 100). This manual is available on the Henny Penny Public website ( Read these instructions completely prior to installation and operation of this appliance to ensure compliance to all required installation, operation and safety standards. Read and obey all safety messages to avoid damage to the appliance and personal injury. This fryer must be installed and used in a way that water does not contact the oil which can cause splashing and boiling over of oil and steam leading to personal injury; excludes normal product moisture. Burn risk! Do not move the fryer or filter drain pan while containing hot oil. Personal injury or serious burns can result from splashing hot oil. This appliance is intended for commercial use in kitchens of restaurants, bakeries, hospitals, etc. but not for the continuous mass production of food such as in a factory setting. During use the units airborne A-weighted emission sound pressure is below 70 db(a). All repairs must be performed by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard. Always use strain relief. The provided power cord must be installed with a strain relief in a way that if the strain relief fails, wires L1, L2, L3 and N must draw taunt and fail first. If the supplied power cord or an existing one becomes damaged, do not use it; rather, replace it with a known good power cord. The powercord must be replaced by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard. Proper daily, weekly, monthly, quarterly and yearly maintenance must be performed on this appliance to ensure safe and continuous operation. This appliance must never be cleaned with a water jet or steam cleaning tool. Cleaning brushes are shipped with the appliance and proper cleaning instructions are included in this manual. Preface Proper maintenance also increases the usable life of the appliance and oil, which reduces lifetime operating costs. Additionally, old oil increases the possibility of surge boiling and fire due to the reduced flash point of the oil. The oil temperature must never exceed 450 F (230 C). This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a x

13 person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance. This appliance is not intended to be operated by means of an external timer or a separate remote control system. Preface xi

14 Preface xii

15 Chapter 1 Overview This chapter outlines basic information needed by installers and operators to safely install and operate the appliance. This appliance is not intended for use by persons (including children) with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. 1.1 Technical Support Call your local service provider or distributor first. For additional help, call or Henny Penny (HP) Technical Support at: Inside the U.S.: or technicalservices@hennypenny.com. Outside the U.S.: or intltechsupport@hennypenny.com. 1.2 Dimensions and Clearance Ensure the appliance is installed with the required clearance. Also refer to 2.2 Selecting The Location, page 5. Table 1-1 Dimensions and Clearance Dimensions Height in. (1454 mm) Height in. (1890 mm) lid up to clean Width in. (610 mm) Depth in. (1030 mm) Clearance Top 6 in. (152 mm) lid up to clean Sides 6 in. (152 mm) air flow Back 6 in. (152 mm) air flow 1Overview

16 Front 38 in. (965 mm) remove drain pan 1.3 Operating Specifications Review the information below to become familiar with the appliance operation. Table 1-2 Operation Specifications Heating 2 immersed elements: each with three heaters watts Capacity Product Fry VAT Oil Oil Reservoir 24 lbs. (11 kg) 8 heads of chicken 83 lbs. (37.6 liters) 15 lbs. (6.8 liters) 1.4 Data Plate Location A data plate located on the front shroud to the left of the nylatron filler strip identifies the fryer model, serial number, warranty date and other information. In addition, the serial number is stamped on the outside of the counter top. Overview 2

17 Chapter 2 Unpacking and Installation This chapter outlines the unpacking and installation requirements. Read and follow the instructions carefully. Fryer must be installed and used in such a way to prevent water from contacting the shortening. Any shipping damage should be noted in the presence of the delivery agent and signed prior to his or her departure. NOTICE Installation of this unit should be performed only by a qualified service technician. This appliance is not intended to be operated by means of an external timer, extension cord or a separate remote control system. 2.1 Unpacking the Appliance Carefully remove the shipping crate and packing. Take care when moving the fryer to prevent personal injury. The fryer weighs approximately 665 lbs (302 kg). Do not puncture the fryer with any objects such as drills or screws, as electrical shock or component damage may result. To avoid personal injury, all counterweights must be installed and secured before attempting to unlatch the lid. 1) Cut and remove the plastic bands from the packing box. 2) Remove the packing box lid, and then lift the remaining packing box sides off the appliance. 3) Remove the 4 corner packing supports. 4) Cut the stretch film from around the carrier/rack box and remove it from the top of the lid. 5) Cut, remove and dispose of the metal bands holding the fryer to the pallet. 3Unpacking and Installation

18 2.1.1 Unloading the Appliance Carefully remove the appliance from the shipping pallet. The following steps requires a two person lift to prevent injury or damage to the appliance. 1. Set the casters in a forward position to prevent unexpected movement. 2. While one installer steadies the appliance, to prevent it from falling off the pallet, pry both side rails off the pallet. 3. Remove the counterweights from beneath the appliance. 4. Either prop a ramp against the pallet for each set of casters, and then roll the appliance off the pallet or lift the appliance off the pallet and set it on the floor Installing Counterweights Counterweights are used to offset the heavy lid, which is used to seal the vat during cooking. Carefully install the counterweights in to the weight carriage. INFO: A half-weight counter balance weight is available for order if the lid lowers by itself due to additional product weight. See Figure 13-7 Front Top View, page 167. Unpacking and Installation Do not drop counterweights or personal injury may result. Each counterweight weighs approximately 20 lbs. (9 kg.) each. To avoid personal injury, all counterweights must be installed and secured before attempting to unlatch the lid. 4

19 1. Remove the top and rear panel covers to access the counterbalance weight carriage assembly. 2. Insert the first through fourth counterweight segments into the counterbalance weight carriage assembly. 3. Remove the two bolts marked A to release the counterbalance weight carriage assembly. 4. Install the rear panel cover, and then the top panel cover. INFO: A half-weight counter balance weight is available for order if the lid lowers by itself due to additional product weight. See Figure 13-7 Front Top View, page Finish Unpacking the Appliance 1. Cut warning tags from lid assembly. 2. Open the carrier by unlatching the lock. 3. Remove the accessories from inside the filter drain pan. 4. Remove the protective paper from the fryer cabinet. 5. Clean exterior surfaces with a damp cloth. 2.2 Selecting The Location The proper location of the appliance is very important for operation, speed, and convenience. Choose a location which provides easy loading and unloading without interfering with the final assembly of food orders. Operators find that frying from raw to finish, and holding the product in a warmer provides fast continuous service. Landing or dumping tables should be provided next to the fryer. The best efficiency is obtained by a straight line operation, i.e. raw in one side and finish out the other side. Order assembly can be moved away with only a slight loss of efficiency. To properly service the fryer, 24 inches (60.96 cm) of clearance is needed on all sides of the fryer including access for servicing by removing a side panel. 5Unpacking and Installation

20 To prevent severe burns from splashing hot oil, position and install fryer to prevent tipping or movement. Restraining ties may be used for stabilization. To avoid fire and ruined supplies, the area under the fryer should not be used to store supplies. 2.3 Leveling The Fryer For proper operation, level the fryer from side to side and front to back. Use a leveling tool on the flat areas around the vat collar and a crescent wrench to adjust the castors. Failure to follow these leveling instructions can result in oil overflowing the vat which may cause serious burns, personal injury, fire and/or property damage. 2.4 Ventilation of the Fryer The fryer should be located with provision for venting into adequate exhaust hood or ventilation system to permit efficient removal of steam exhaust and frying odors. The exhaust canopy must be designed to avoid interference with the operation of the fryer. Consult a local ventilation or heating company to help in designing an adequate system. Unpacking and Installation NOTICE: Ventilation must conform to local, state, and national codes. Consult your local fire department or building authorities. 2.5 Electrical Requirements This fryer must be adequately and safely grounded (earthed) or electrical shock may result. Refer to local electrical codes for correct grounding (earthing) procedures or in absence of local codes, with The National Electrical Code, ANSI/NFPA No. 70-(the current edition). In Canada, all electrical connections are to be made in accordance with CSA C22.1, Canadian Electrical Code Part 1, and/or local codes. To avoid electrical shock, this appliance must be equipped with an external circuit breaker which will disconnect all ungrounded (unearthed) conductors. The main power switch on this appliance does not disconnect all line conductors. 6

21 The electric fryer requires 208, 240 or 480 volt, three phase, 50/60 Hertz service. The power cord may be already attached to the fryer, or provided at installation. Check the data plate to determine the correct power supply. A separate disconnect switch meeting over-voltage category III conditions with proper capacity fuses or breakers must be installed at a convenient location between the fryer and the power source. It should be an insulated copper conductor rated for 600 volts and 90 C. For runs longer than 50 feet (15.24 m), use the next larger wire size. 2.6 International Electrical Requirements Units being used outside the United States may not be shipped with the power cord attached to the unit because of the different wiring codes. The fryers are available from the factory wired for 200, 240, 380 and 415 volts, 3 phase, 50 Hertz service. A terminal block is mounted inside the fryer for the cable wiring. For equipment with CE mark only; to prevent electric shock hazard this appliance must be bonded to other appliances or touchable metal surfaces in close proximity to this appliance with an equipotential bonding conductor. This appliance is equipped with an equipotential lug for this purpose. The equipotential lug is marked with the following symbol. NOTICE: CE units require a minimum wire size of 4 mm to be wired to the terminal block. If a flexible power cord is used, it must be HO7RN type. The supply power cords shall be oil-resistant, sheathed flexible cable, no lighter than ordinary polychloroprene or other equivalent synthetic elastomer-sheathed cord. It is recommended that a 30 ma rated protective device such as a residual current circuit breaker (RCCB), or ground fault circuit interrupter (GFCI), be used on the fryer circuit. 7Unpacking and Installation

22 Unpacking and Installation 8

23 Chapter 3 Initial Startup 3.1 Loading Setpoints In general, default cook menus with product settings such as Wings, Fries, Fish, etc. are entered in to the unit during the manufacturing process. These preset products can be deleted or modified by operators as necessary to meet business requirements, refer to Chapter 8 Programming, page 65. Some companies prefer their operators download proprietary setpoints from a corporate website using a USB drive and then loading them on to the units. This ensures product (cook) menu items are current. It also makes menu item updates across many units quick and easy for operators. The following steps explain the process for loading the software file. INFO: Sometimes a pre-loaded USB drive is shipped with the unit per customer request. 1) Once the.xml setpoint file is downloaded to a USB drive, insert the USB drive in to the external USB port on the front of the unit. 2) Press and hold the Main Menu button until *MAIN* displays. Refer to 4.2 Controls and Indicators, page 17. 3) Select 3. USB/DATA from the Main Menu. Refer to 4.5 Main Menu, page 18. 4) Select 2. Setpoints from the USB/DATA menu. 5) Select GET FROM USB from the setpoint menu. A password prompt displays. 6) Enter 123. Setpoint files display. 7) Press the up and down arrows to locate the file to be loaded. 8) Press the or right-arrow button to select the desired file. LOAD? displays. 9) Select YES. The file loads. -DONE- displays when complete. 10)Press the or right-arrow button. A menu displays. 11)Select 3. REMOVE USB. Ok To Remove displays. 12)Remove the USB drive, and then press X to exit back to normal operation. 9Initial Startup

24 3.2 Drain Pan Assembly Use these steps after disassembling and cleaning the drain pan, to install a new filter and reassemble the filtration system and pan assembly. NOTICE During assembly be sure to apply oil to all O-rings to lubricate and to help prevent tears and oil loss. 1. Slide a filter envelope on to the filter screen so the plug is protruding through the hole. 2. Slide the two handle clamps on to the ends of the filter screen assembly with the handles facing the plug. 3. Place the filter screen in the bottom of the drain pan with the plug side up. 4. Align the hole in the pickup tube with the filter screen plug, and then press down. 5. Position the pick-up tube so that both sides of the guides slide in to the holder bracket notches. 6. Press down on the pick-up tube to confirm it is fully engaged on the filter screen plug. 7. Place the crumb catcher into the drain pan so the legs straddle the filter screen. 8. Place the lid onto drain pan. Initial Startup 9. Push the drain pan into place and lock it into place using the locking latch. 10

25 3.3 Initial Oil Fill Read all warnings and then proceed to Purge the Oil Lines, page 11. Failure to follow these instructions may result in oil overflowing the frypot which could cause serious burns, personal injury, fire and/or property damage. Do not manually stir the oil at any time. Brush all cracklings from the frypot surfaces during daily cleaning. The fryer must be setting level. Be certain the oil is never above the upper oil fill line. Use recommended product load size (maximum 24 lbs.). It is recommended that a high quality frying oil be used in the pressure fryer. Some low grade oils have a high moisture content and cause foaming and boiling over. The oil level must always be above the heating elements when the fryer is heating and at the vat level indicators on the rear of the vat. Failure to follow these instruction may result in a fire and/or damage to the fryer Purge the Oil Lines Before filling the vat with frying oil for the first time, purge the oil lines to ensure all water or mineral oil is removed. Also wipe out the vat to remove dust or other debris. 1) Turn the unit on. 2) Press and hold the menu button until *MAIN* displays. 3) Select 1. FILTER from the menu. 4) Press the menu button once. The 6. FILL menu displays. 5) Select 6. FILL from the menu. The fill pot (vat) menu displays. 6) Press and hold PUMP (hold). Oil pumps in to the vat. 7) Release the PUMP (hold) button when lines are purged. 8) Wipe out the vat with a clean disposable towel. Initial Startup 11

26 3.3.2 Manually Fill the Vat The vat has 2 level indicator lines inscribed on the rear wall. The upper line is the fill limit for hot oil. The lower line is the fill limit for cold oil. 1. Fill the vat with cold new oil to the lower limit line. 2. Power on the unit to begin normal operation Bulk Fill the Vat If you have a bulk oil supply system connected to the appliance you can fill the vat using the control panel. The vat has 2 level indicator lines inscribed on the rear wall. The upper line is the fill limit for hot oil. The lower line is the fill limit for cold oil. 1) Turn the unit on. 2) Press and hold the menu button until *MAIN* displays. 3) Select 1. FILTER from the menu. 4) Press the menu button once. The 6. FILL menu displays. 5) Select 6. FILL from the menu. The fill pot (vat) menu displays. 6) Press and hold PUMP (hold). Oil pumps in to the vat. 7) Release the PUMP (hold) button when the oil reaches the oil line. Initial Startup 12

27 3.4 Fill the Fresh Oil Tank The fresh oil tank automatically tops off the oil in the vat when it senses the vat s oil level is low. Operators should add new oil to the fresh oil tank as needed. Do not add new oil directly to the vat unless performing an oil disposal cycle. Refer to 6.6 Oil Disposal, page 30 for oil disposal steps. After three failed attempts to fill the vat from the fresh oil tank, the fill oil tank message displays: The upper display reads FILL OIL TANK. The middle display flashes, representing the location of the tank. Fill the fresh oil tank by doing the following: 1. Pull out the fresh oil tank. 2. Open the fresh oil tank lid and locate the marks on the inside wall of the tank. 3. Using new oil, fill the fresh oil tank to the marks on the inside of the tank. 4. Shut the fresh oil tank lid, and then slide back into position. 5. Press the OK button on the control panel. Initial Startup 13

28 Initial Startup 14

29 Chapter 4 Operation 4.1 Operating Components This section lists the major components of the fryer. Figure 4-1 KFC Item No. Description Function 1 Carrier A counterbalanced carrier with a handle that a multitray rack assembly slides on to, holding up to 8 head of product. The multi-tray rack assembly is raised and lowered in to the vat of oil as the carrier is raised and lowered. 2 Power Switch Turns the power (electricity) to the appliance on/off. To ensure the complete deactivation of the appliance and all its components, unplug the unit from the wall outlet. 3 Movable Rear Caster Wheel Provides mobility for precise positioning of the appliance. 4 Oil Drain Pan Oil in the vat is drained in to this pan for cleaning, filtering and disposal. Operation 15

30 Item No. Description Function 5 Stationary Front Caster Wheel Provides stability for precise positioning of the appliance. 6 Fresh Oil Tank Filled with new oil, the appliance pulls fresh oil from this reservoir when the low oil sensor detects additional oil is needed. Never over fill the reservoir or vat. 7 Control Panel (Board) Used to program, control and operate the appliance. 8 USB Port Used to upload software changes to the control panel. Operation 16

31 4.2 Controls and Indicators This section provides an overview of the control board. Figure 4-2 KFC Item No. Feature Function 1 Arrow Icon Arrow buttons are used to navigate menus. 2 Plus Sign Icon Used to change the value of the currently displayed item. 3 Minus Sign Icon Used to change the value of the currently displayed item. 4 Info (Information) Button Press once to display the pressure and temperature. Press twice to activate the wipe feature. Press three times to access the last filter information. 5 Product Buttons Used as pre-programmable product buttons. 6 Main Menu Button Press and hold to access the Main menu. 7 Action Buttons When a light illuminates or an icon displays next to a button it is active, press the button to perform the displayed action. Operation 17

32 4.3 Action Buttons The functions of the action buttons can vary based on the nature of the currently displayed setting: Arrow buttons are used to navigate (step through) programmable items. Small triangle symbols highlight the value of the currently displayed item. Number buttons, or plus and minus buttons (+,-) are used to change the value of the currently displayed item. Numeric values are entered calculator style using the number buttons. Alphanumeric text values are entered using the number buttons to select characters from a scrolling list of all available characters for the currently active language. Multiple-choice items, where two or more predefined options are available, are selected by using the plus and minus buttons (+,-) to scroll through the list of available options. For example, the plus and minus buttons (+,-) might be used to choose Yes or No for a particular setting, or to choose On or Off, or to step through a list of several options like English, French, German, Spanish, etc. 4.4 Mode Overview Some options appear multiple times throughout the menus but behave differently depending on the mode the unit is logged in to, such as normal operation verses manager or technician mode. A hard coded password is used when logging in to a secure mode to protect the integrity of the system settings from accidental or malicious actions. Also, some options are intentionally redundant such as the exit menu which always displays as the last menu item with the same functionality regardless of mode or menu. 4.5 Main Menu Access the main menu by pressing and holding the Main Menu button, located at the lower-left corner of the control panel. Once the menu activates, release the button. To select a menu item, press and release the lighted button next to it. Menu items may activate other menus or may activate various programming modes. If a function menu has multiple pages, press and release the Menu button to step through them. After the last page of the menu, the display circles around to the first page again. The x. EXIT MENU option, if available, always appears as the last item in the function menu. Select the x. EXIT MENU option to exit the menu without choosing any of the offered items. The main menu options display as follows: Operation 18

33 Menu (screen) 1 Menu (screen) Menu Structure This section provides a high level visual overview of the menu structure. 4.7 Display Options To change the display option see 8.5 Special Programming, page 73 and the Chapter 8 Programming, page 65 for information on setting up menus. This section describes three individual display options. Operation 19

34 Title Option The 4+TITLE option displays up to four cook items along with the title of the menu. When in a cook menu, the title of the menu displays in the top section. Pressing the left or right arrow button allows you to scroll through each menu option. Pressing the item you want to cook starts the heating process. DROP is displayed when the unit is ready to cook the selected item Next Option The 5+NEXT option shows up to five cook items, along with a button that steps to the next cook menu. All the cook options are displayed on the screen with the bottom-right reading next. Press next to access the next set of cook options Items Option The 6 ITEM option lets the user control all six items on the cook menu. Operation If there is more than one cook menu, the user must program navigation links to other menus. If there are more than 6 products, and this option is selected, one of the buttons must be designated as a link to a sub-menu, or those options will not be accessible. 20

35 Chapter 5 Oil Maintenance This unit was designed to operate with a reduced amount of oil as compared to previous models. Additionally it is designed with software driven controls that optimize oil life. Typically operators can expect 30 days of useful life from one vat of oil before replacement is required. These results vary based on the amount and frequency of product cooked and the operators adherence to a consistent maintenance schedule, which includes operator specific settings, filtering and polishing frequency, and cooking habits. NOTICE: To lengthen oil life and to keep product quality high do not skip oil filtration. The proper level of cooking oil is automatically maintained as long as the fresh oil tank is filled. See 3.4 Fill the Fresh Oil Tank, page 13 for procedures for filling the fresh oil tank. 5.1 W.A.S.S.H. W.A.S.S.H. is an acronym that Henny Penny uses to describe the environmental elements that breaks down oil prematurely, shortening the useful life of the oil, which drives up the cost of ownership. They are as follows: Water - Moisture naturally occurring in product along with other sources of water degrades oil. Reducing water contamination by filtering often and cleaning off excessive ice crystals before dropping product can extend the life of the oil. Air - Oil slowly oxidizes when it is in contact with air. Properly maintaining the fryer mechanically and hygienically, and following recommended cooking procedures can reduce oil usage. Close the lid when the unit is not in use. Salt - Salt within product and breading makes its way in to the oil during the cooking process. Reducing additional salt contamination by following best practices when breading, cooking, and seasoning product increases oil life. Never season or shake excess breading off over a vat of oil. Soap - Soap residue, even in undetectable amounts, left behind after the washing process degrades oil. Ensure vats are rinsed thoroughly after washing to protect oil life. Heat - The controls are designed to make frying product the most efficient process as possible. Following best practices when using the Henny Penny fryer ensures the longest oil life possible. One best practice is selecting a product menu and placing the fryer in Cool Mode when not in use. Oil Maintenance 21

36 5.2 Boil-Over Prevention The following rules are provided to prevent personal injury to the operator and damage to the appliance. Failure to follow these instructions can result in oil overflowing the vat which may cause serious burns, personal injury, fire and/or property damage. The oil may be stirred only during the morning start up procedure. Do not stir the oil at any other time. Brush all cracklings from vat surfaces during the vat clean out process. Make sure the unit is sitting on a stable surface and has been leveled during installation before use. Be certain the oil is never above the vat upper fill line. Be certain that the gas control valve and burners are properly adjusted (gas units only). Do not overload the racks with product (24 lbs. (10.9 kg) maximum), or place product with extreme moisture content into racks. Always use a high quality frying oil. Some low grade oils have a high moisture content and cause foaming and boiling over. When it is necessary to drop frozen product, dip the basket of product in the oil for just a moment and then remove. Wait a moment and then place the basket of product back in to the vat, and then start the timer. Oil Maintenance 5.3 Filtering Filtering prolongs the life of the oil, the unit as well as improves product quality. There are various ways to filter the oil. As an example, a quick filter automatically runs between cook cycles to clean the oil and remove debris from the vat. A daily filter is run at the end of the day to thoroughly clean the unit. A polish is a prolonged filtration cycle used to extend the useful life of the oil. This section explains how to access and navigate the filtration menus. With prolonged use, the flashpoint of the oil the point at which oil bursts in to a flame is reduced. Discard oil immediately if it shows signs of excessive smoking or foaming. Serious burns, personal injury, fire, and/or property damage may result. 22

37 INFO: Drain the oil at 250 F (121 C) or less. Higher temperatures cause cracklings to burn on the steel vat surfaces after the oil has drained Filter Menus 1) Press and hold the Menu button until *MAIN* displays. Refer to 4.5 Main Menu, page 18. 2) Select 1. FILTER from the menu. Menu options display. 3) Push the Menu button repeatedly to access additional menus. Menu (screen) 1 Menu (screen) 2 Menu (screen) 3 Menu (screen) Quick Filter The 1. QUICK option allows operators to perform a quick filter of the oil on-demand. A quick filter runs automatically after every cook cycle. During the filtering cycle the oil does not fully drain. It maintains a constant level during filtering. Arrows pointing up and down with a sequence of tracing light displays. Oil Maintenance 23

38 1. Select 1. QUICK FILTER. A confirm prompt displays. If the operator selects: NO x, the display returns to the previous menu. YES, the drain opens automatically and the oil begins filtering. After a few moments, the drain closes and the oil returns to the vat. When the vat is close to full, the control panel chirps and a display timer starts counting down. If the unit does not detect the oil returning to the vat and displays IS POT FILLED?, check the oil level to confirm the vat is full. If the oil is: Level with the hot fill line on the back of the vat, press YES. Not level with the hot fill line on the back of the vat, press NO x. The filter pump motor runs for an additional 30 seconds and pumps oil from the drain pan Daily Filter The 2. DAILY option allows operators to perform a daily filter of the oil and a wash cycle if desired. This filter cycle drains the oil from the vat completely enabling the user to clean the crumbs out of the vat and wash then down the drain. The crumb catcher in the drain pan holds the debris and the filter cleans the oil. 1. Select 2. DAILY. A confirm prompt displays. If the operator selects: Oil Maintenance NO x, the display returns to the previous menu. YES, the drain opens automatically and the oil begins draining. As the oil drains a brush symbol displays. Then three prompts display: FILL, WASH, DRAIN. The control attempts to detect when the pot does not empty properly. The control monitors the main temperature probe, and looks for it to begin cooling at a predetermined rate, as evidence that the oil has drained down below the probe and 24

39 the probe is now air cooling. If by the end of the initial -Draining- step, the control has not detected sufficient temperature cooling on the main temperature probe, the control activates a display that graphically represents a blocked drain, and displays the messages DRAIN BLOCKED?, CLEAR THE DRAIN. The display continues until the expected cooling rate is observed on the main probe, or until the operator presses a button to acknowledge the message. Do the following: 2. Select the WASH option and the wash cycle begins, WASHING displays. Once completed, the display returns to the previous menu. Press STOP at any time to discontinue wash. 3. Press FILL to return the filtered oil to the vat. After a few moments, the drain closes and the oil returns to the vat. When the vat is close to full, the control panel chirps and a display timer starts counting down. Press STOP at any time to discontinue fill. If the unit does not detect the oil returning to the vat or if the vat sensor detects the oil is below the full line the message IS POT FILLED? displays. Check the oil level to confirm the vat is full. If the oil is: Level with the hot fill line on the back of the vat, press YES. Not level with the hot fill line on the back of the vat, press NO x and the filter pump motor runs for an additional 30 seconds Polish The 3. POLISH option extends the usable life of the oil by removing debris through an extended polishing (filtration) process. An automatic polish to help increase the life of the oil automatically occurs during the morning startup, after every cook cycle, and during the daily filter. To manually start a polish, do the following: Oil Maintenance 25

40 1. Press 3. POLISH. A confirm prompt displays. If the operator selects: NO x, the display returns to the previous menu. YES, the drain opens automatically and the oil begins draining. Downward pointing arrows display indicating the vat is draining. A 15 minute timer displays and starts. The oil cycles repeatedly through the drain pan filtration system until the timer expires, ultra cleaning the oil, also referred to as a polish. When the polish cycle completes, the display indicates that the oil is returning to the vat. The control panel chirps and a timer starts. Once the timer counts down, IS POT FILLED? displays. If the unit does not detect the oil returning to the vat or if the vat sensor detects the oil is below the full line the message IS POT FILLED? displays. Check the oil level to confirm the vat is full. 2. If the oil is: Level with the hot fill line on the back of the vat, press YES. Not level with the hot fill line on the back of the vat, press NO x and the filter pump motor runs for an additional 30 seconds. Oil Maintenance 26

41 Chapter 6 Maintenance The following cleaning procedures ensures the fryer is sanitary while keeping product quality high and downtime to a minimum. 6.1 Regular Maintenance Schedule This appliance requires care and proper maintenance. The table below provides a summary of scheduled maintenance. The following table provide preventive maintenance procedures to be performed by the operator. Table 6-1 Regular Maintenance Schedule Change the oil. Procedure Change the filter envelope. Clean the vat. Clean the drain pan. Clean the caster wheels. Clean ATO reservoir. Clean the nylatron filler strips. Inspect and clean all pressure components on units primarily used for open frying. Frequency As required - Refer to 6.6 Oil Disposal, page 30 Daily - Refer to 3.2 Drain Pan Assembly, page 10 Daily - Refer to 6.7 Clean-Out Mode, page 38 Daily - Refer to Clean the Drain Pan, page 29 Weekly - Refer to 6.4 Clean the Castor Wheels - Weekly, page 29 Weekly - Refer to Clean the Fresh Oil Tank (ATO), page 29 Monthly - Refer to 6.5 Cleaning Nylatron Filler Slides - Monthly, page 30 Semi-annually (Every 6 months) - Refer to and 6.2 Wipe Mode This appliance is equipped with a WIPE mode. This mode gives 10 seconds to wipe the control board clean of any debris without activating the control buttons. Maintenance 27

42 6.3 General Cleaning - Daily 1. Press the Info (information) button twice. 2. Press the button to confirm. 3. The control board starts a count down timer set for 10 seconds. 4. Once the 10 seconds expires, the control returns to the previous screen. Always clean the fryer after the oil has cooled, and be sure to cover the vat(s) with a clean sheet pan to protect the oil from debris, water and soap splashes during the cleaning process. Empty the condensation drain pan and rinse it out with clean water. Clean the drain pan and replace the filter Daily Filter A daily filtering of the oil is essential to prolong the life of the oil and the unit. This unit uses less oil than traditional fryers so attention must be paid to the build-up of crumbs and cooking debris in the bottom of the vat(s). A quick filter runs after every cook cycle to keep the oil clean and debris to a minimum; however, a daily filter allows for a more thorough cleaning of the oil, vat, drain pan and a filter change. 1) Perform a daily filter cycle. Refer to Daily Filter, page 24. Maintenance Wipe Down the Unit Wiping down the outside of the unit is a sanitary practice that presents a professional appearance and improves product quality. While the unit is in Daily Filter mode do the following: 1) After covering the vat(s) with a sheet pan, use warm, soapy water and a cleaning sponge to wipe down the external components of the unit. Keep the sponge dry as possible to prevent the warm, soapy water from splashing in to the vat, contaminating the oil. 2) Clean around the vat band being careful not to drip water or drop debris in to the vat. 3) Wipe off the nylatron filler strips. Once a month a more thorough cleaning is required. Refer to 6.5 Cleaning Nylatron Filler Slides - Monthly, page 30. 4) Once the daily filter cycle is complete, clean the control board after enabling Wipe Mode. Refer to 6.2 Wipe Mode, page

43 6.3.3 Clean the Fresh Oil Tank (ATO) INFO: Not used in bulk fill applications. The fresh oil tank (box) is a storage tank of fresh oil for the Automatic Top Off (ATO) system. Daily pull the tank out half-way, lift the lid, and then top off with fresh oil. As necessary, pull the tank out, clean, and then refill with fresh oil. While the daily filtering process is cycling do the following: NOTICE: Inspect the fresh oil tank o-rings and replace if damaged or every 90 days. 1) Pull out the fresh oil tank halfway and open the lid. Refer to 3.4 Fill the Fresh Oil Tank, page 13 and Chapter 4 Operation, page 15. 2) Pull the tank out half way and then lift up, continue pulling out the tank. 3) Empty the oil in to a bulk oil disposal container. 4) Clean the tank with warm soapy water, and then rinse thoroughly. 5) Dry thoroughly, and then install the tank back in to the unit. 6) Add fresh oil to the tank as required. 7) Close the lid and carefully push the fresh oil tank back in to place Clean the Drain Pan The drain pan is a self-contained assembly underneath the unit that filters and polishes the oil to prolong oil life. In addition it catches and holds debris such as breading that falls off product during the cooking cycle. Once the daily filter process completes do the following: NOTICE: Inspect the drain pan o-rings and replace if damaged or every 90 days. 1) Carefully pull the drain pan assembly out from under the unit. 2) Remove the lid, clean, dry, and then set aside. 3) Remove the crumb catcher, clean, dry, and then set aside. 4) Remove the filter assembly. 5) Remove the filter envelope and discard. 6) Clean, dry, and then set aside the filter assembly components. 7) Clean, dry, and then set aside the drain pan. 8) Refer to 3.2 Drain Pan Assembly, page 10, install a new filter envelope, and then reassemble the drain pan. 9) Insert the drain pan under the unit until it latches. 6.4 Clean the Castor Wheels - Weekly Spray Henny Penny biodegradable, food safe, foaming degreaser (part no.12226) on castor wheels at least once a week as part of the normal cleaning routine. This prevents the long term build up of grease and dirt which can inhibit the normal operation of the wheels. Wheels laden with grease and dirt may stick or stop rolling Maintenance 29

44 which can make the fryer wobbly and unstable when moving. An unstable fryer can spill oil or tip over, causing damage to the fryer or serious personal injury. 6.5 Cleaning Nylatron Filler Slides - Monthly The Nylatron Filler Strips prevent food debris from entering the inside of the unit. Keeping them clean prolongs the life of the strips. Missing, broken or worn strips must be replaced. Or the internal mechanics of the unit becomes clogged with oil and food debris. 1. Spray Henny Penny biodegradable, food safe, foaming degreaser (part no.12226) on Nylatron filler strips. 2. Raise the lid up and down several times to spread the degreaser. 3. Wipe the Nylatron filler strips to remove food soil, grease, and degreaser residue. Maintenance 6.6 Oil Disposal Oil disposal is unique to each fryer. Three unique oil disposal types are available; manual, rear or front disposal. The manual method of bulk oil disposal, which requires a mobile cart Oil Disposal Shuttle (ODS), replaces the filter drain pan during the disposal process. The oil is drained directly from the vat in to the cart. Once the cart is full it is removed and taken to a bulk oil container where it is emptied. This process is repeated until the vat is drained of old unusable oil. The rear disposal process requires an on site external bulk oil disposal container which is permanently connected to the rear of the fryer by tubing. The oil is pumped from the rear of the fryer to a remote bulk oil container. The front disposal method requires a portable tank or external bulk oil disposal container that uses a hose to connect to a spigot on the front of the fryer, just to the left of the drain pan. The disposal type must be initially selected in the Special Programming menu by the installer at setup. If the disposal method changes over time the setting can be modified as required. Refer to 8.5 Special Programming, page 73, SP-17 menu for detailed instruction. 30

45 6.6.1 Dispose Menu Overview Select the 1. FILTER menu, and then press the Main menu button twice to select 7. DISPOSE and perform disposal tasks. Menu (screen) 1 Menu (screen) 2 Menu (screen) 3 Menu (screen) Manual Oil Disposal This section explains the manual process for draining and disposing of oil. Once the oil has degraded, the vat is drained completely and refilled with new oil. The degraded oil is manually transported to an oil storage container, using an Oil Disposal Shuttle (ODS). Use PPE. Oil can be dangerously hot. Allow the oil to cool to 100 degrees before removing. Hot oil should not be manually transported in a non-approved container, even for short distances. Always use an Oil Disposal Shuttle (ODS) or approved container, such as a metal pan with insulated handles and a locking lid. Ensure the drain pan is empty prior to preforming these procedures. The ODS and all metal pans transfer heat, which can cause serious burns. Pumping hot oil through the ODS damages the pump over time. NOTICE: Access the Dispose Menu To protect community sewer lines, oil must be trapped and disposed of through bulk removal. Hot oil can coagulate when cooled, which clogs pipes and sewer lines. Always dispose of oil in to an approved bulk oil disposal storage container or approved grease trap. Never pour oil down a public sanitation drain. Henny Penny recommends using an automated bulk oil disposal system, or a manually operated Oil Disposal Shuttle (ODS) to drain degraded oil from the vat and transport it to an approved oil disposal storage container. Use the following steps to access the disposal menu. Maintenance 31

46 Use PPE. Moving a drain pan containing hot oil may cause splashing and serious burns can result. Always pump the oil back in to the vat from the drain pan and dispose in to the ODS shuttle. NOTICE: An indicator procedure. light displays next to active options during 1) Press and hold the Main menu button until *MAIN* displays. The Main menu displays. 2) Press the 1. FILTER button. Additional menu items display. 3) Ensure the drain pan is empty and then do the following: If the drain pan is empty, press the Main menu button twice, and then continue at Drain the Oil, page 32. If the drain pan contains oil: a). Press the Main menu button once, then press 5. FILL. b). Wait, oil pumps up to the vat. c). Press the Main menu button once, and then continue at Drain the Oil, page Drain the Oil Using an Oil Disposal Shuttle (ODS) drain the oil from the vat by doing the following: Use PPE. The ODS 300 holds approximately half the volume of oil contained in the vat. To prevent splashing and spillage, drain no more than half of the oil in to the ODS 300 at one time. Maintenance 1) Put on Personal Protective Equipment (PPE). 2) Remove the drain pan and insert the ODS. Ensure the ODS's lid is open and the drain spigot aligns with the ODS opening. WARNING!: Do not overfill the oil disposal shuttle. Hot oil overflowing onto the floor may cause severe burns and / or a fall risk. 3) Press the 7. DISPOSE button. The message =DISPOSE= IS CART OR PAN IN PLACE? and YES NO displays. 4) Press the YES button. DRAIN (hold) displays. 5) Press and hold the DRAIN (hold) button until the ODS is half-full, then release. 6) Remove the ODS carefully to prevent splashing and spillage, and then close and lock the lid. 7) Transport the ODS to an approved oil storage container and empty. 8) Repeat steps 5 through 7, making multiple trips until the vat is empty. 32

47 Purge the Fittings Degraded oil remains inside the lines, valves and fittings. To completely purge the degraded oil, do the following: 1) Press the next button. The message =PURGE= Pump new oil push old oil from ports displays. 2) Press the PUMP button. The pump runs for a few seconds, new oil pumps in to the vat, then the pump stops. 3) If necessary, press the PUMP button again to ensure the lines, valves and fittings are purged. 4) Press the next button. The = WIPE = OPEN DRAIN option displays. 5) Press the OPEN DRAIN button. OPENING... displays. Oil drains from the vat. =WIPE= Wipe pot with cloth or paper towel displays Wipe Out the VAT To ensure degraded oil does not mix with new oil, do the following: 1) Use a cloth or paper towel to wipe the remaining oil down the vat drain and clean the vat surface. 2) Remove the ODS carefully to prevent splashing and spillage, and then close and lock the lid. 3) Transport the ODS to an approved oil storage container and follow ODS procedures to empty the oil. 4) When done, store the ODS in a safe location Fill the Vat with Oil Fill the vat with new oil by doing the following: 1) Press the next button. EXIT DISPOSE? and YES NO displays. 2) Press YES. - OFF - displays. 3) Clean and dry the drain pan and install a new filter. Refer to 3.2 Drain Pan Assembly, page 10 for instructions. 4) Insert the drain pan under the unit. 5) Align and push the quick disconnect filter tube, on the drain pan, in to the filter tube receptacle on the bottom of the unit. 6) Fill the vat to the lower limit line with fresh oil. 7) Power on the fryer unit and return to normal operation Rear Bulk Oil Disposal This section explains the bulk oil process for draining and disposing of oil. Once the oil has degraded, the vat is drained completely and refilled with new oil. The degraded oil is pumped in to a bulk oil storage container using menu commands from the fryer's control board. Maintenance 33

48 NOTICE: To protect community sewer lines, oil must be trapped and disposed of through bulk removal. Hot oil can coagulate when cooled, which clogs pipes and sewer lines. Always dispose of oil in to an approved bulk oil disposal storage container or approved grease trap. Never pour oil down a public sanitation drain Access the Dispose Menu Use the following steps to access the disposal menu. An indicator light displays next to active options during procedure. 1) Press and hold the Main menu button until *MAIN* displays. The Main menu displays. 2) Press the 1. FILTER button. Additional menu items display. 3) Press the Main menu button twice. The dispose menu displays Drain the Oil Drain the oil from the vat by doing the following: 1) Press the 7. DISPOSE button. The message DRAIN POT? and YES NO displays. 2) Press the YES button. DRAINING displays. 3) Wait. The oil from the vat drains in to the drain pan. When complete, the message =PURGE= Pump new oil push old oil from ports displays Purge the Fittings Degraded oil remains inside the lines, valves and fittings. To completely purge the degraded oil, do the following: 1) Press the PUMP button. The pump runs for a few seconds, new oil pumps in to the vat, then the pump stops. 2) If necessary, press the PUMP button again to ensure the lines, valves and fittings are purged Wipe Out the Vat Maintenance To ensure degraded oil does not mix with new oil, do the following: 1) Put on Personal Protective Equipment (PPE). 2) Use a cloth or paper towel to wipe the remaining oil down the vat drain and clean the vat surface. 3) When done, press the next button. A dispose, pump oil to waste tank message displays Rear Disposal of the Oil - Only INFO: If set for Front Disposal the bulk oil hose is connected to the front of the fryer continue to Front Disposal of the Oil - Only, page

49 To pump the degraded oil from the drain pan to the bulk oil storage container, do the following: 1) Press the PUMP button. STOP displays. 2) Wait. The pump begins siphoning the oil out of the drain pan. 3) When the drain pan is emptied of oil, press the STOP button. 4) Continue at next step: If you fill the vat manually continue at, Fill the Vat Manually, page 35. If you fill the vat from bulk continue at, Fill the Vat from Bulk, page Fill the Vat Manually Fill the vat with new oil by doing the following: 1) Press the next button. EXIT DISPOSE? and YES NO displays. 2) Press the YES button. CLOSING... and then - OFF - displays. 3) Remove, clean and dry the drain pan and install a new filter. Refer to 3.2 Drain Pan Assembly, page 10 for instructions. 4) Insert the drain pan under the unit until it latches. 5) Manually fill the vat, by pouring oil from a container, to the lower limit line with new oil. 6) Power on the unit and return to normal operation Fill the Vat from Bulk Fill the vat with new oil by doing the following: 1) Press the next button. EXIT DISPOSE? and YES NO displays. 2) Press the YES button. CLOSING... and then - OFF - displays. 3) Remove, clean and dry the drain pan and install a new filter. Refer to 3.2 Drain Pan Assembly, page 10 for instructions. 4) Insert the drain pan under the unit until it latches. 5) Press the Add <- New button until the oil reaches the lower limit line with new oil. 6) Power on the unit and return to normal operation Front Bulk Oil Disposal This section explains the bulk oil process for draining and disposing of oil. Once the oil has degraded, the vat is drained completely and refilled with new oil. The degraded oil is pumped in to a bulk oil storage container using menu commands from the fryer's control board. Maintenance 35

50 NOTICE: To protect community sewer lines, oil must be trapped and disposed of through bulk removal. Hot oil can coagulate when cooled, which clogs pipes and sewer lines. Always dispose of oil in to an approved bulk oil disposal storage container or approved grease trap. Never pour oil down a public sanitation drain Access the Dispose Menu Use the following steps to access the disposal menu. An indicator light displays next to active options during procedure. 1) Press and hold the Main menu button until *MAIN* displays. The Main menu displays. 2) Press the 1. FILTER button. Additional menu items display. 3) Press the Main menu button twice. The dispose menu displays Front Disposal Reminder - Connect the Hose INFO: Rear dispose systems should always have the hose connected to the fryer, so no such reminder displays. If set for front disposal (hose), the control displays a reminder to connect the hose between the fryer and the disposal cart (tank). Confirm that the hose is securely connected on both ends at the tank and at the fryer then press the YES button to proceed Drain the Oil Drain the oil from the vat by doing the following: 1) Press the 7. DISPOSE button. The message DRAIN POT? and YES NO displays. 2) Press the YES button. DRAINING displays. 3) Wait. The oil from the vat drains in to the drain pan. When complete, the message =PURGE= Pump new oil push old oil from ports displays Purge the Fittings Maintenance Degraded oil remains inside the lines, valves and fittings. To completely purge the degraded oil, do the following: 1) Press the PUMP button. The pump runs for a few seconds, new oil pumps in to the vat, then the pump stops. 2) If necessary, press the PUMP button again to ensure the lines, valves and fittings are purged Wipe Out the Vat To ensure degraded oil does not mix with new oil, do the following: 1) Put on Personal Protective Equipment (PPE). 36

51 2) Use a cloth or paper towel to wipe the remaining oil down the vat drain and clean the vat surface. 3) When done, press the next button. A dispose, pump oil to waste tank message displays Front Disposal of the Oil - Only INFO: If set for Rear Disposal the bulk oil hose is connected to the rear of the fryer continue to Rear Disposal of the Oil - Only, page 34. To pump the degraded oil from the drain pan to the bulk oil storage container, do the following: 1) Press the PUMP button. 2) Wait. The pump begins siphoning the oil out of the drain pan. 3) When the drain pan is emptied of oil, or the bulk oil storage container is full, release the PUMP button. WARNING! Do not overfill the oil disposal shuttle. Hot oil overflowing onto the floor may cause severe burns and / or a fall risk. INFO: Depending on the size of the bulk oil disposal container, this procedure may need to be performed several times to fully drain the vat. Release the PUMP button at any time to stop pumping. 4) Continue at next step: If you fill the vat manually continue at, Fill the Vat Manually, page 37. If you fill the vat from bulk continue at, Fill the Vat from Bulk, page Fill the Vat Manually Fill the vat with new oil by doing the following: 1) Press the next button. EXIT DISPOSE? and YES NO displays. 2) Press the YES button. CLOSING... and then - OFF - displays. 3) Remove, clean and dry the drain pan and install a new filter. Refer to 3.2 Drain Pan Assembly, page 10 for instructions. 4) Insert the drain pan under the unit until it latches. 5) Manually fill the vat, by pouring oil from a container, to the lower limit line with new oil. 6) Power on the unit and return to normal operation Fill the Vat from Bulk Fill the vat with new oil by doing the following: 1) Press the next button. EXIT DISPOSE? and YES NO displays. 2) Press the YES button. CLOSING... and then - OFF - displays. Maintenance 37

52 3) Remove, clean and dry the drain pan and install a new filter. Refer to 3.2 Drain Pan Assembly, page 10 for instructions. 4) Insert the drain pan under the unit until it latches. 5) Press the Add <- New button until the oil reaches the lower limit line with new oil. 6) Power on the unit and return to normal operation. 6.7 Clean-Out Mode After the initial installation of the fryer and during every oil change, the vat must be thoroughly cleaned. There are two ways to clean the vat using the clean-out mode, heated and cold soak. Operators can fill the vat with warm water and cleaning solution, enable heat, and then scrub the vat immediately (P.M.) or let it soak overnight cold and scrub it in the morning (A.M.). Cleaning the vat immediately is called a Heated Clean-Out and allowing the vat to soak overnight is called a Cold- Soak Clean-Out. The choice of which type of clean-out an operator uses is set during installation within the software settings. Refer to Drain and dispose of the oil before performing these procedures. Refer to 6.6 Oil Disposal, page 30 for instructions. Maintenance 38

53 Do not close lid with water and/or cleaner in vat. Water under pressure becomes superheated. When lid is opened, escaping water and steam can result in severe burns. Always wear chemical splash goggles or face shield and protective rubber gloves when cleaning the vat as the cleaning solution is highly alkaline. Avoid splashing or other contact of the solution with your eyes or skin. Severe burns and possible blindness can result. Carefully read the instructions on the cleaner. If solution comes in contact with your eyes, rinse thoroughly with cool water and see a physician immediately. Do not use steel wool, or other abrasive cleaners or cleaners/sanitizer containing chlorine, bromine, iodine or ammonia chemicals, as these deteriorate the stainless steel material and shorten the life of the unit. NOTICE: Do not use a water jet (pressure sprayer) to clean the unit, or component damage may result. Do not bang brushes or scrapers on the pot band. Damage to the pot band may cause gaps around the gasket disallowing pressure to build when sealed. Make sure the inside of the vat, the drain valve opening, and all parts that come in contact with the new oil are as dry as possible Setting the Clean-Out Mode Type Operators can choose between a Heated and a Cold-Soak clean-out. To select a clean-out mode refer to 8.5 Special Programming, page 73, SP-22 through SP Clean-Out Menu Overview Select the 1. FILTER menu, and then press the Main menu button twice to select 8. CLEAN-OUT and perform clean out tasks. Maintenance 39

54 Menu (screen) 1 Menu (screen) 2 Menu (screen) 3 Menu (screen) Access Clean-Out Mode Use the following steps to access the Clean-Out menu. An indicator light displays next to active options during procedure. 1) If necessary, drain and dispose of the old unusable oil. Refer to 6.6 Oil Disposal, page 30 for instructions. 2) Press and hold the Main menu button until *MAIN* displays. The Main menu displays. 3) Press the 1. FILTER button. Additional menu items display. 4) Press the Main menu button twice. The 8. CLEAN-OUT menu displays. 5) Press the 8. CLEAN-OUT button. =CLEAN OUT= HAS OIL BEEN REMOVED? YES NO displays. 6) Press YES. IS VAT FILLED WITH WATER & CLEANER? displays. 7) Proceed to Perform the Clean-Out Preparation, page Perform the Clean-Out Preparation 1) Remove the racks and carrier. 2) Fill the vat with warm water half way to the oil level indicators. This can be done with a 5 gallon bucket or water hose connected to a spigot. 3) Add 8 to 10 ounces of fryer cleaning solution. 4) Continue to Perform the Cold-Soak Clean-Out, page 40 or Perform the Heated Clean-Out, page 41. Maintenance Perform the Cold-Soak Clean-Out This procedure requires that the water stays in the vat overnight to soak off the crusty debris on the side of the vat. 1) If necessary, press the OFF button to power off the unit. 2) Allow the vat, filled with water and cleaner, to soak as long as necessary (overnight). 3) Use a scrub brush/pad on the vat walls to loosen any crumbs or debris. 4) Carefully clean the elements with a thin scrub brush. 5) Scrub the underside of the lid. 6) Remove and clean the lid gasket. 40

55 7) When completely scrubbed clean, press the DONE button. DONE SOAKING?, YES and NO displays. 8) Press YES, and then press the next button. 9) Proceed to Drain the Water, page Perform the Heated Clean-Out This procedure requires immediate cleaning without soaking overnight. 1) If necessary, press the ON button to power on the unit. =CLEAN OUT= HEATING 78F x! displays. 2) WAIT. The temperature rises to 194 degrees, and then a 15:00 minute timer starts with a beeper sounding. =CLEAN OUT= cleaning displays. 3) Use a scrub brush/pad on the vat walls to loosen any crumbs or debris. 4) Carefully clean the elements with a thin scrub brush. 5) Scrub the underside of the lid. 6) Remove and clean the lid gasket. The time on the timer runs out. =CLEAN OUT= *DONE*, and then TURN FRYER OFF displays. 7) Press the power off button. =DRAIN= DRAIN (hold) and next displays. 8) Proceed to Drain the Water, page Drain the Water A bucket, tub or the drain pan needs to be in place under the drain before proceeding to draining. If using the drain pan, remove all the internal parts so the pan is empty. Do not put the lid on the pan it must remain open for this procedure. 1) Press and hold the DRAIN (hold) button. Draining water, and then drain small amount to pan and then dump displays. The water drains in to the bucket/tub/ pan. 2) When the bucket/tub/pan is partially full, release the button and the water stops draining. 3) Remove the bucket/tub/pan from under the fryer and dispose. 4) Repeat steps 3 and 4 in this section until the vat is completely drained. 5) Press the next button. IS POT EMPTY? displays. 6) Confirm all the water is drained from the vat, and then press YES. 7) Proceed to Rinse the Vat With Clean Water, page Rinse the Vat With Clean Water During this procedure when the drain is open, all the water, cooking debris, and cleaner exits the bottom of the unit. The control board does not regulate, warn or display the amount of flow through the unit in to the bucket/tub/pan, this must be done manually. Do not overflow the bucket/tub/pan. Maintenance 41

56 INFO: Some fryer cleaning solutions require a vinegar rinse. Please check product instructions. 1) Ensure the bucket/tub/pan is under the drain. OPEN DRAIN displays. 2) Press OPEN DRAIN. The drain opens. 3) Use clean water to rinse the side walls and bottom of the vat. 4) Stop when the bucket/tub/pan is full or the unit is rinsed clean. 5) Press the CLOSE DRN button. 6) Remove the bucket/tub/pan from under the fryer and dispose. 7) Repeat steps 2 through 5 until the vat is rinsed clean of cooking debris, cleaner and dirty water. 8) Press the CLOSE DRN button. 9) Ensure the bucket/tub/pan is under the drain. 10)Press the next button. =PURGE= PUMP displays. 11)Proceed to Purge the Oil Lines, page Purge the Oil Lines Clear dirty, unusable oil, water and debris from the oil lines by doing the following: 1) Confirm the fresh oil tank has new oil in it. 2) Press and hold the PUMP button until clean, fresh oil comes through the jets in the bottom of the vat. 3) To clear the oil from the vat, refer to Rinse the Vat With Clean Water, page 41. 4) Once the vat is rinsed, press the next button. ==WIPE== OPEN DRAIN display. 5) Proceed to Wipe the Vat, page Wipe the Vat Ensure the tilt stop (kickstand) is engaged. Lid may fall with force if tilt stop (kickstand) is not engaged. Failure to engage the tilt stop (kickstand) may result in serious injury or product damage. Maintenance 1) Place a bucket/tub/pan under the fryer. 2) Press the OPEN DRAIN button. 3) Use a clean towel to wipe the sides and bottom of the pot. Guide all the remaining water and debris down the drain. 4) Press the CLOSE DRN button to close the drain. 5) Remove the bucket/tub/pan from under the fryer and dispose. 6) Press the next button. EXIT CLEAN-OUT? displays. 42

57 7) Proceed to Exit Confirmation, page Exit Confirmation 1) If the clean-out process is completed, press the YES button. If the drain is open, the control board automatically closes the drain. KEEP OFF UNTIL FILLED displays. 2) If the power switch is in the ON position, move it to the OFF position to power off the unit. 3) Fill the vat with fresh oil to the lower oil indicator line on the side of the vat. 4) Once the vat is filled with fresh oil, the fryer is ready for normal operations. Maintenance 43

58 Maintenance 44

59 Chapter 7 Semi-annual and Annual Inspections A certified technician should inspect all pressure components semi-annually (once every 6 months). A certified technician should inspect the entire fryer annually (once every 12 months). Use the Chapter 15 Annual and Semi-annual Inspection Checklist Form, page 177 below to ensure all required maintenance procedures are completed. 7.1 Inspect Castors and Frame Ensure the fryer s castors are clean and operational by doing the following. A cracked frame creates a tipping risk. If cracked frame is found, immediate attention is needed to repair the frame by having it professionally repaired by a welder, or having the fryer replaced. Ensure the fryer sits level, casters are mechanically sound and able to hold the weight of the fryer, and that the tube steel frame is not cracked or bent. If the fryer is not level, inspect the condition of the floor. Repair the floor as necessary, have any missing or cracked tiles replaced. If there is a slope due to a floor drain, the fryer may need to be repositioned so the caster is on level flooring. Casters on the fryer cannot be adjusted up or down. Inspect casters and the tube steel frame by removing the side panels and using a flashlight to look for cracks and/or bent framing. Replaced any damaged or broken casters by doing the following: Semi-annual and Annual Inspections 45

60 1. Raise the lid to lower the fryer s center of gravity. 2. Discard oil from the fry pot. 3. Remove the racks from the carrier. 4. Position two floor jacks under the frame (A), near the casters (B), on the same side of the fryer. 5. Block the casters on the opposite side of the fryer with small wheel chocks. 6. Raise the fryer approximately 2.5 (63mm). 7. Use an adjustable wrench to remove the caster (B). 8. Use an adjustable wrench to install the new caster. Ensure a snug fit but do not overtighten. Semi-annual and Annual Inspections 7.2 Inspect Counterweight Cables 9. Continue to the next inspection or reinstall components as applicable. This unit uses two cables in the counter-weight mechanism that helps in the raising and lowering of the lid. Cables should be visually inspected yearly, either as part of a planned maintenance program or during a routine service call. Cables more than 10 years old should be replaced regardless of inspection results. Call for service to have both cables replaced. : If the lid becomes difficult to operate, stop using the fryer and call for service because the cables need to be replaced. 46

61 Worn Counterweight Cable Usable Counterweight Cable 1. Use a 3/8 socket, to remove the 6 keps nuts around exterior of rear cover and remove the back shroud. 2. Inspect the counter-weight cables. If cables have cracks in the jacket, missing pieces in the jacket, or other obvious signs of wear, replace both cables. 3. Continue to the next inspection or reinstall components as applicable. 7.3 Inspect and Lubricate the Carriage Wheels The carriage wheels inside the back of the fryer should be lubricated at least once a year to allow for easy lid movement. Semi-annual and Annual Inspections 47

62 1. If necessary, use a 3/8 socket to remove the 6 keps nuts around exterior of rear cover and remove the back shroud. 2. Inspect the carriage wheels and ensure proper operation. 3. Use spindle lube (PN 12124) and place a small amount on all four (4) wheels, both top and bottom, left and right rollers. 4. Continue to the next inspection or reinstall components as applicable. Semi-annual and Annual Inspections 7.4 Oil Migration Inspect behind the left side panel for excessive oil seeping through either the high limit pot fittings, the temperature probe pot fitting, level probe fitting, pressure transducer fitting, or the heating element fittings. If oil migration or seepage is found, remove and clean the fittings, applying pipe thread sealant and then re-install the fitting. If excessive oil migration is discovered, the insulation on the side of the fryer must be replaced. To avoid serious personal injury: Unplug fryer before removing the left side panel to prevent electrical shock. Only perform this procedure when the fryer is cool or severe burns may result. 1. If necessary, remove the left side panel. 2. Inspect for oil seepage at the probe fittings, high limit fittings, pressure transducer fitting and heating element fittings. 3. Complete any necessary repairs. 4. Continue to the next inspection or reinstall components as applicable. 48

63 7.5 Inspect Fry Pot for Leaking Excessive oil accumulation on the exterior of the fry pot may indicate the fryer is having a hardware issue or the operator is not following recommended operating procedures. Oil accumulation on the exterior of the frypot creates a fire risk. Take the fryer out of service until the oil accumulation is removed, or the fryer is replaced. With both side panels and the back shroud removed, clean off the oil accumulation, and then use a flashlight to inspect the fry pot, fry pot welds, fry pot plumbing and fittings, and the probe and element fittings. If the fry pot is suspected of leaking, do the following: If the oil accumulation is toward the upper half of the fry pot, take the fryer out of service immediately, and replace the fryer. If the oil accumulation is toward the lower half of the fry pot, and it is not evident if the oil accumulation is due to the store using a drain pan without a cover or other operator error, do the following: If necessary, scrape and clean off the existing oil from the fry pot and welds, and then have the store bread and cook 4 head or greater of bone in chicken. During cooking, monitor the suspected area for leaking: If oil is pushed out of the fry pot or welded areas while the fryer is under pressure, take the fryer out of service and replace the fryer. Semi-annual and Annual Inspections 49

64 If the pot is not leaking, take the fryer out of service until the oil accumulation is removed and the store operates the fryer with a drain pan cover or the operator error is corrected. 7.6 Temperature and Level Probe Inspection Ensure the temperature and level probes are undamaged and working within specification by doing the following: To avoid serious personal injury. Unplug fryer before removing the left side panel to prevent electrical shock. Only perform this procedure when the fryer is cool or severe burns may result. Semi-annual and Annual Inspections 50

65 1. Press and hold the menu button until *MAIN* appears on the display. 2. Press the number one product button to enter the filter menu. 3. Press the right arrow until 4. DRAIN -> displays. 4. Select 4. DRAIN ->, and drain all the oil in the fry pot into the drain pan. 5. On the inside of the vat, clean off any build up or debris from the temperature probe and level probe. If a probe is bent or damaged, replace the probe. 6. Check that each probe is inserted into the fry pot 3/8 into the oil. If a probe either extends too far into the oil or is too shallow, do the following: a) Remove the left side panel. 7.7 Inspect the Power Cable b) Adjust the probe to the correct depth by loosening the ½ compression nut on the temperature probe. c) Slide the probe to the correct depth then tighten the compression nut. 7. Select 5. FILL <-. Allow oil to fully fill the vat. Once filled, cancel the filter pump motor and exit out of the filter menu by pressing and holding the menu button. 8. Continue to the next inspection or reinstall components as applicable. Replace any power cord with torn or damaged sheathing, any exposed wire, or any fraying. Replace the plug if there are any signs of damage, loose wires showing, or burnt connections. Semi-annual and Annual Inspections 51

66 Fire Risk and Electrical Shock Possible. If any of these conditions are found, take the fryer out of service until a new power cord or plug can be installed. Always adhere to local electrical code upon installation of the power cord. This fryer must be adequately and safely grounded (earthed) or electrical shock could result. Refer to local electrical codes for correct grounding (earthing) procedures or in absence of local codes, with The National Electrical Code, ANSI/NFPA No. 70-(the current edition). In Canada, all electrical connections are to be made in accordance with CSA C22.1, Canadian Electrical Code Part 1, and/or local codes. To avoid electrical shock, this appliance must be equipped with an external circuit breaker which will disconnect all ungrounded (unearthed) conductors. The main power switch on this appliance does not disconnect all line conductors. Semi-annual and Annual Inspections NOTICE: FOR EQUIPMENT WITH CE MARK ONLY! To prevent electric shock hazard this appliance must be bonded to other appliances or touchable metal surfaces in close proximity to this appliance with an equipotential bonding conductor. This appliance is equipped with an equipotential lug for this purpose. The equipotential lug is marked with the following symbol. The supply power cords shall be oil-resistant, sheathed flexible cable, no lighter than ordinary polychloroprene or other equivalent synthetic elastomer-sheathed cord. It is recommended that a 30 ma rated protective device such as a residual current circuit breaker (RCCB), or ground fault circuit interrupter (GFCI), be used on the fryer circuit Electrical Requirements The electric fryer requires 208 or 240 volt, three phase, 50/60 Hertz service. The power cord may be already attached to the fryer, or provided at installation. Check the data plate mounted just above the lid, on the left side of the back shroud, to determine the correct power supply. A terminal block is mounted inside the fryer for the cable wiring. A decal on the inside of the right side panel will help in the wiring of the unit. Refer to 2.5 Electrical Requirements, page 6. 52

67 7.7.2 International Requirements Units being used outside the United States may not be shipped with the power cord attached to the unit because of the different wiring codes. The fryers are available from the factory wired for 208, 240, 380 and 415 volts, 3 phase, 50 Hertz service. A terminal block is mounted inside the fryer for the cable wiring. A decal on the inside of the right side panel will help in the wiring of the unit. Refer to 2.6 International Electrical Requirements, page High Limit and Module Inspection Ensure the high limit and module are undamaged and working within specification by doing the following: Never leave a fryer with a high limit bypassed. This can lead to fire, property damage, personal injury or death. To avoid serious personal injury. Unplug fryer before removing the left side panel to prevent electrical shock. Only perform this procedure when the fryer is cool or severe burns may result. Semi-annual and Annual Inspections 53

68 1. Locate the two high limit control modules mounted on the left hand side of the shroud behind the control. 2. Visually inspect the modules for cracks, broken or loose terminals. 3. Visually inspect the high limit momentary reset switch and ensure it works. Semi-annual and Annual Inspections 4. Follow red wire RHL 1 from the control board and make sure that it is securely attached to the terminal on the lower module. If this wire is not connected, reconnect it to match the diagram on the left. 5. Follow red wire RHL 2 from the control board and make sure that it is securely attached to the terminal on the upper module. If this wire is not connected, reconnect it to match the diagram on the left. 6. Make sure red wire HLJ connects the two modules as shown in the drawing on the left. 7. Verify all other wires attached to the high limit modules have secure connections. 8. Continue to the next inspection or reinstall components as applicable. 54

69 7.9 Measuring Amp Draw Ensure that the amp draw of the fryer equals the amp draw listed on the data label. Why is this important? If amp draw is less than what is on the data label, this would be an indication that one of the phases that comes into the fryer may be missing, there may be an issue with one of the contactors, or there may be an issue in one of the fire bar heating elements. HIGH VOLTAGE PRESENT! This procedure should only be performed by a service technician who is trained and understands electrical safety. 1. Attach an amp meter (amp clamp style) to one of the upper heating element s wires. 2. Connect power to the fryer, turn on the controls, and then set to call for heat. Once the fryer calls for heat, measure and note amp draw. 3. Repeat steps 1 2 for each of the other upper heating element s wires connected to the upper heater. The amp draw should be close to the same for each of the wires. 4. Repeat steps 1 2 for each of the lower heating element s wires connected to the lower heater. The amp draw should be close to the same for each of the wires. 5. Add the amp reading from all six wires together, and then divide by The figure should equal what is listed on the data label. 6. If this figure is lower than what is on the data label, then troubleshoot to find the issue with either incoming power, the contactor or the heater assemblies. 7. Continue to the next inspection or reinstall components as applicable. Semi-annual and Annual Inspections 55

70 7.10 Drain Pan Component Inspection Ensure the drain pan components are undamaged and working within specification by doing the following: Do not attempt this inspection until the fryer has had time to cool, otherwise severe burns may result. Only perform this procedure when the drain pan is cool. 1. Remove the drain pan and disassemble. 2. Verify the filter screen, two o-rings, and both filter clips are in place and assembled correctly. If any of these parts are missing or damaged, replace them. Semi-annual and Annual Inspections 7.11 Testing the Drain Valve 3. Verify the standpipe and three o-rings are assembled correctly and not missing or damaged. 4. Verify the crumb basket and lid are not missing or damaged and if any components are missing or damage, replace them. 6. Continue to the next inspection or reinstall components as applicable. Ensure the drain valve is undamaged and working within specification by doing the following: 56

71 1. Press and hold the menu button until *MAIN* appears on the display. 2. Press the number one product button to enter the filter menu. 3. Press the right arrow until 4. DRAIN -> displays. 4. Select 4. DRAIN ->. 5. Once all the oil drains into the drain pan, visually inspect the drain and valve. 6. Ensure the drain valve is fully open and not partially closed, which indicates the valve assembly may be misaligned or needs replaced. 7. Select 5. FILL < Bulk Dispose Test 8. Ensure the drain valve is fully closed and not partially closed, which indicates the valve assembly may be misaligned or needs to be replaced. 9. Allow oil to fully fill the vat. 10. Once filled, cancel the filter pump motor and exit out of the filter menu by pressing and holding the menu button. 11. Continue to the next inspection or reinstall components as applicable. Ensure the bulk dispose process is working within specification by doing the following: NOTICE: Before performing this procedure, make sure the bulk oil system is securely connected to the dispose port on the fryer and the quick disconnect is engaged. Semi-annual and Annual Inspections 57

72 1. Press and hold the menu buttonuntil *MAIN* appears on the display. 2. Press the number one product button to enter the filter menu. 3. Press the right arrow until 4. DRAIN -> displays. 4. Select 4. DRAIN ->, and then cancel after draining about 2 of oil in the fry pot. 5. Press the right-arrow until 7. DISPOSE displays. 6. Select 7. DISPOSE and let the motor run for about 1 min., and then stop the pump. 7. Wearing PPE, pull out the drain pan and verify the oil pumped out of the drain pan and into the bulk oil system. Semi-annual and Annual Inspections a) If oil pumped out of the drain pan, exit out of the filter menu by pressing and holding the menu button. b) If oil did not pump out, troubleshoot dispose plumbing, selector valve issues etc. 8. Continue to the next inspection or reinstall components as applicable. INFO: Replenish the oil in the fry pot by pouring oil from a jug or from bulk oil as applicable Heating Element Spreader Bars Tightening and Inspection Ensure the heating element spreader bars are undamaged and working within specification by doing the following: 58

73 To avoid serious personal injury: Unplug fryer before removing the left side panel to prevent electrical shock. Only perform this procedure when the fryer is cool or severe burns may result. 1. Press and hold the menu button until *MAIN* appears on the display. 2. Press the number one product button to enter the filter menu. 3. Press the right arrow until 4. DRAIN -> displays. 4. Select 4. DRAIN ->, and drain all the oil in the fry pot into the drain pan. 5. Using a Phillips screwdriver, check the tightness of the screws on all four spreader bars. INFO: Do not overtighten screws. If any spreader bar is missing or any of the spreader bar screws are missing, replace them. 6. Select 5. FILL <-. Allow oil to fully fill the vat. 7. Once filled, cancel the filter pump motor and exit out of the filter menu by pressing and holding the menu button. 7. Continue to the next inspection or reinstall components as applicable Oil Return Diverters and Pressure Outlet Inspection Ensure the oil return diverters and pressure outlet are undamaged and working within specification by doing the following: Semi-annual and Annual Inspections 59

74 To avoid serious personal injury: Unplug fryer before removing the left side panel to prevent electrical shock. Only perform this procedure when the fryer is cool or severe burns may result. 1. Press and hold the menu button until *MAIN* appears on the display. 2. Press the number one product button to enter the filter menu. 3. Press the right arrow until 4. DRAIN -> displays. 4. Select 4. DRAIN ->, and drain all the oil in the fry pot into the drain pan. 5. Use a Phillips head screwdriver, and remove the screws on each of the oil return diverters located at the bottom of the fry pot. Semi-annual and Annual Inspections 6. Remove both oil diverters and o-rings. 60

75 7. Clean and remove debris from the oil return tube at the bottom of the fry pot. 8. Clean the oil diverters by removing all debris from the narrow opening. 9. If the o-rings are not cracked or damaged reuse them, otherwise replace them. 10. Reinstall the oil diverters, ensuring that the opening is aimed to return oil in the directions shown. 11. Select 5. FILL <-. Allow oil to fully fill the vat. Once filled, cancel the filter pump motor and exit out of the filter menu by pressing and holding the menu button. 12. Continue to the next inspection or reinstall components as applicable Inspect for Plumbing Leaks in the Filtration System Ensure the filtration pump, tubing and connectors are undamaged and working within specification by doing the following: To avoid serious personal injury: Unplug fryer before removing the left side panel to prevent electrical shock. Only perform this procedure when the fryer is cool or severe burns may result. Semi-annual and Annual Inspections 61

76 1. Use a flashlight to inspect the fittings of the filtration plumbing and between the filter pump and motor for oil leaks. 2. Press and hold the menu button until *MAIN* appears on the display. 3. Press the number one product button to enter the filter menu. 4. Press the right arrow until 4. DRAIN -> displays. 5. Select 4. DRAIN ->, and drain about half of the oil in the fry pot into the drain pan. Semi-annual and Annual Inspections 7.16 Inspect Cam Slide Fillers 6. Select 5. FILL <-, and pump the oil back in to the fry pot. 7. While the oil is pumping, use a flashlight to inspect for oil leaks. If leaks are detected: - In the plumbing, disassemble, clean and reassemble fittings using pipe thread sealant on tapered thread fittings and/or replace any flex lines, and/or compression fittings as applicable. - In the filter pump and motor, disassemble and replace the seal (and rollers) with a new seal kit. Inspect the cam slide fillers on the sides of the lid cover. If either side is damaged or missing, replace with new cam slide fillers. Why is this important? The cam slide fillers help minimize the amount of grease laden vapor, breading, dust and debris that can accumulate on the components under the lid cover. 62

77 To avoid serious personal injury: Do not operate without lid cover in place and all components installed. Do not tamper with any component of the lid locking mechanism during operation. Do not attempt this procedure while the fryer is in use or the fry pot is hot. Severe burns may result. Only perform this procedure when the fryer is cool and disconnected from the power source. 1. Remove old left and right cam slide fillers if necessary by pulling the remaining pieces out of its channel and discarding. 2. Install the new left and right cam slide fillers by flexing open the slot in the circular opening Replacement Maintenance Parts 3. Fit the new cam slide filler around the circular handle cam, ensuring the edge of the filler is inserted into the channel. 4. Reinstall the lid cover, ensure the cam slide fillers are completely seated on the inside of the cover. 5. Test that the handle slides forward and backwards with little resistance. Stoppage or resistance usually indicates an obstruction present in the channel, or that the slide is not seated properly. 6. Continue to the next inspection or reinstall components as applicable. Operators must replace normal wear parts (items) to maintain the safe reliable operation of the unit Ordering Parts Use only genuine Henny Penny parts in this unit. Using a lesser quality substitute part may result in damage to the unit or personal injury. Your service provider or distributor Semi-annual and Annual Inspections 63

78 has a parts price list and will be glad to provide you with part(s) costs. Commonly replaced items are stocked by your service provider or distributor and are sent out when your order is processed. Less common parts ordered from Henny Penny by your service provider or distributor normally take three working days. All replacement parts (except lamps and fuses) are warranted for 90 days against manufacturing defects and workmanship. If damage occurs during shipping, notify the carrier at once so that a claim may be properly filed. Refer to the warranty for other rights and limitations Parts List These are commonly replaced parts that are ordered due to normal wear, accidental breakage or loss. Table 7-1 Replacement Maintenance Parts Qty. Part # Description When to Replace DRAIN PAN O-RING SUCTION LINE Used to seal the oil tubing connections. Replace every 90 days or sooner if cut, flattened or missing O RING - CRUMB SWEEP Ports in the bottom of the vat where fresh oil enters during a cleaning cycle to wash across the bottom of the vat. Replace as required. Semi-annual and Annual Inspections DRAIN PAN FILTER ENVELOPES NYLATRON FILLER STRIP KIT LID COUNTER- WEIGHT CABLE Used inside the drain pan as apart of the filtration assembly. Replace at least daily, more often as required. Used to cover slots to prevent food debris, oil and water from entering the internal mechanics of the unit. Replace when broken. Used to connect the lid assembly to the carriage weight assembly in the back of the unit to offset the lid weight. Replace cables when worn. 64

79 Chapter 8 Programming 8.1 Program Menu From the MAIN menu, refer to 4.5 Main Menu, page 18, select 4. PROG, and then 1. PRODUCTS. 8.2 Product Programming Menu Access the Product Programming menu by doing the following: 1) Press and hold the menu button until *MAIN* displays. 2) Press the menu button again. The 4. PROG menu displays. 3) Select 4. PROG. 4) Type 123. The 1. PRODUCTS menu displays. 5) Select 1. PRODUCTS. The Products menus display. 6) Use the left or right arrow to navigate through the options. This section describes how to program a new product into an empty slot or override a current product. 1. Press the + or - button to scroll through the list to create or select a product to program. 2. Press the right-arrow to program the selected product. 3. Press CHANGE to create a name. The name becomes the displayed title. 4. Press the left or right arrows to navigate screens 1 through 5. Screen 1: A B C D E F G H I J Screen 2: K L M N O P Q R S T Screen 3: U V W X Y Z + - / Screen 4: Programming 65

80 Screen 5: Ins Del Clr 5. Press the number buttons, 1 through 0, to select an option. 6. Press the button to confirm completion. 7. Press the right-arrow button. LINK ID displays. The Link ID is an abbreviation for the cook menu. 8. Change the Link ID by pressing the change button. 9. Press the number buttons to set the name. 10. Press the right-arrow button. COOK TIME displays. 11. Press the number buttons to set the cook time. 12. Press the right-arrow button. STEP 2 AT displays. STEP 2 AT determines the time the next Set Temperature settings activate. 13. Press the number buttons to set the time. 14. Press the right-arrow button. STEP 3 AT displays. Programming Enter 0:00 at anytime and this automatically ends the cook cycle. 15. Use the right-arrow button. TEMP 1 displays. 66

81 16. Press the number buttons to set the temperature. 17. Press the right-arrow button. TEMP 2 displays. 18. Press the number buttons to set the temperature. 19. Press the right-arrow button. ALARM 1 displays. 20. Press the number buttons to set the alarm. 21. Press the right-arrow button. LOAD COMP displays. 22. Press the number buttons to set the LOAD COMP (Load Compensation) value. INFO: A setting of 0 disables the Load Compensation feature. 23. Press the + or - button to set the LOAD COMP REF (Load Compensation) to SETPT (Setpoint) or OTHER. If OTHER is selected, press the rightarrow button and continue at step 24. LC REF TEMP displays. Otherwise continue at step Press the number buttons to set the temperature for the load compensation calculation to reference. 25. Press YES to confirm. 26. Press the right-arrow button. FULL HEAT displays. Programming 67

82 Full heat is the amount of time the heat is applied full force (thermostatically) at the start of the cook cycle, before the control switches over to PC (pulsed control) heating. 27. Press the number buttons to set the time. 28. Press YES to confirm. 29. Press the right-arrow. PC FACTOR displays. 30. Press the number buttons to set the temperature range for pulsed heating. Set to 0 for full heat. This is the number of degrees below setpoint during cooking at which pulsed heat is used, which can help avoid overshoots. The smaller the setting, the more it approaches thermostatic heat control. 31. Press YES to confirm. 32. Press the right-arrow button. BATCH SIZE REQD displays. Batch size required, is used for units with Online Projection Systems. 33. Select YES, and the operator is prompted to enter a batch size after product is cooked. Programming 8.3 Product Programming Mode While in the Product Programming menu, refer to 8.2 Product Programming Menu, page 65, press the MENU button once to access the Product Programming Mode screen. This screen displays additional maintenance options to assist with programming products that can be used in the cook menu. Select a menu item to copy (replicate), and then follow the on-screen prompts. EXIT PROG - Exit without making changes. COPY - Allows operators to copy (Px to Py) one menu item to another. ERASE PROD - Allows operators to delete one pre-programmed menu and add an operator specific menu item. Refer to 8.2 Product Programming Menu, page

83 ERASE ALL - Allows operators to delete all pre-programmed menus and add operator specific menu items. Refer to 8.2 Product Programming Menu, page Copy Menu Items Use this feature to copy (replicate) any product (Px) in to any other product (Py). As an example, the cook settings for 2 Head of chicken is manually entered item by item into product P1. P1 is then copied in to P2 as a starting point for programming the 4 Head settings. If the products are similar, it is much easier to modify the 4 Head settings than to enter in all of the settings manually. To copy, do the following: 1. Select 2. COPY. Copy from product number displays on the left and the copy to product number displays on the right. 2. Press the + or - button to select any product to copy from, and any product to copy too. 3. Press and hold the INFO button to view the product name. Release to return to the previous screen. Programming 69

84 4. Press the YES button. The confirmation screen displays. 8.4 Info Mode Menu Overview 5. Press the YES button. The left-side product is copied in to the right-side product position. The original product (left side) is not affected in any way. The rightside product is completely overwritten by the settings from the left-side product. -DONE- displays, and then select product displays. To access the information menu from the Main menu, press the 2. INFO MODE button. Refer to4.6 Menu Structure, page 19. INFO: An alternate way to access Info Mode is to press and hold the Menu and Info buttons simultaneously until =INFO MODE= flashes on the display. Menu Item E-Log (Error Log Codes) Last Load Function Table 8-1 Info Mode Menu Function Displays the history of the previous 25 error codes starting with the most recent code first. Codes includes the date and time that the error occurred. Displays information about the most recent cook cycle, including total cook time, early stops, if timer is left beeping too long and min./max./avg. temperatures. Daily Stat (Statistics) Displays operating statistics for each of the past seven days, including hours on, cook cycles, number of filters, etc. Programming Review Usage Activity Log Displays ongoing accumulations of operating statistics, which continues to accumulate until a manual reset is performed. To reset (requires password), navigate to the bottom of the list. Displays history of Activity Log events as: On/Off Start/Stop Cook Filter Pan Removed or Replaced 70

85 Menu Item CPU Info (Information) Temperatures Function Displays live temperature reading for the CPU (controller), software version, and software part number. Displays live readings for main oil, level probe, and the bottom of vat temperature. (Digital) Inputs- 1 - Signal present - - No signal present A - Power Switch H - High Limit D - Drain Switch Jumper S - Power Switch Interlock F - Fan Switch Jumper (Digital) Inputs- 2 - Signal present - - No signal present 24dc - 24 DC Supply Pan - Filter Drain Pan *Lid - Lid Liner Pin Lid Liner Pin shows OK if pin is down Lid Liner Pin shows PR when pin is raised (under pressure) (Bulk Oil) Inputs-3 - Signal present - - No signal present DTF - Discard Tank Full FULL - Discard tank is full and cannot dispose to it OK - Discard tank not full, okay to dispose Pressure Inputs n/a Manifold Pressure Fryer Outputs Displays pump pressure reading if optional transducer is installed in plumbing manifold as: * - On - - Off otherwise displays NO SENSOR. * - On - - Off Programming 71

86 Menu Item Function Pri - Primary Contactor Ht - Heat (regulating) Contactor Pr - Pressure Solenoid (n/a) BSV - Bulk Supply Valve (optional) Drain Valve (Control) Status Par - Partially open Stp - Forced Stop Opn - Fully Open Cls - Fully Closed - The current state of the drain valve At - indicates the drain valve position 0 - Fully Closed Fully Open Selector Valve (Bulk Oil Fryers Only) Displays in the lower right with the current port position as: No Selector Valve - unit is not equipped with a Bulk Oil System E=001 - Encoder Position Displays in the lower left with the activity of the valve as: Pump Outputs STPD - Stopped FWD - Forward REV - Reverse * - On - - Off Fltr - Filter Pump ATO - Top Off Pump Bulk - Bulk oil Supply Programming Analog Inputs Memory (Status) Info (Information) (MEM INFO) Displays analog input readings directly from ADC chip displayed as volts and as ADC counts (bits). Use the up and down arrows to step through available inputs. Displays the status and size of the control s internal microsd storage memory as: - Memory OK X - Memory problem 72

87 Menu Item USB Drive Status (USB INFO) Function If installed, displays the status and size of the USB flash drive as: - Flash Drive OK X - Flash Drive not present or drive error hcc - 16 is normal if no USB drive is plugged in ATO (Auto-Topoff) Level LVL - Levels Scroll down to see flash drive volume name. FULL LOW Displays when an assessment is not possible Delta - Displays the temperature difference between the main probe and the level probe. Cnt - Count shows how many ATO pulses have been generated in the current top-off attempt. OPS Radio If OPS and QPM are enabled, displays the ZigBee radio status as: - Good communication in past 15 seconds - - No good message for 15 to 60 seconds X - No good message for 60+ seconds Press the down arrow to view: Join status Channel number PAN ID Radio ID Reset (un-join) button 8.5 Special Programming Access the Special Programming menu by doing the following: INFO: Starting with v1.60, initializing operations performed in Special Program mode no longer reset the product settings and cook menus to default values. 1) Press and hold the menu button until *MAIN* displays. 2) Press the menu button again. The 4. PROG menu displays. 3) Select 4. PROG. Programming 73

88 4) Type 123. The 3. SPCL PROG menu displays. 5) Select 3. SPCL PROG. The Special Program menu displays. 6) Use the left or right arrow to navigate through the options. Table 8-2 Special Program Menu Function Menu Display Name Function SP-1 TEMP UNIT Press the plus or minus button to select either FAH- RENHEIT ( F) or CELSIUS ( C). SP-2 LANGUAGE Press the plus or minus button to scroll through a list of languages. Press a language to select. INFO: Supports the Russian language for v1.60 or higher. SP-3 SYSTEM INIT Press the hold-> button for three seconds to reset the controls to factory defaults. SP-4 SP-4A OPS/QPM SYSTEM ENABLED? OPS/QPM USE COOK ID CODE Press the plus or minus buttons to enable or disable the OPS or QPM wireless communications for this control. Requires an optional radio module. Press the plus or minus button to select: YES - to apply user specific programmable numbers to identify each product. NO - to always use the default product number to identify each product. SP-5 SP-6 AUDIO VOLUME (Loudness) AUDIO TONE (Frequency) Press the plus or minus button to adjust the volume (loudness) of the speaker between 1-10, then press the TEST button to test the loudness. Press the plus or minus button to adjust the frequency (tone) setting, then press the TEST button to test the tone. SP-7 MELT CYCLE Press the plus or minus button to select either the SO- LID or LIQUID melt mode heating cycle. SP-8 START-UP POLISH ENABLED? Press the plus or minus button to select either YES or NO to specify whether an automatic polish operation should be performed as part of the normal morning startup process. Programming SP-9 SP-10 START-UP GO WHERE? COOK MENUS OPTIONS Press the plus or minus button to select a default cook menu that displays after exiting the melt mode. Press the plus or minus button to navigate through cook menu options. 4+TITLE 5+NEXT 6 ITEMS 74

89 Menu Display Name Function Refer to 3.3 Display Options section of the Operator s Manual. SP-11 SP-12 SP-13 SP-14 COOK MENU BUTTONS COOK DONE GO WHERE? AUTO-MENU MINUTES AUTO-MENU GO WHERE? Press the plus or minus button to select: SELECT - to begin preheating when a cook menu button is pressed. COOK - to begin the cook cycle immediately. Press the plus or minus button to select the default cook menu to display after each cook cycle completes. Press the plus or minus button to select a time in minutes. When a selected product begins preheating, and the drop temperature is reached but a cook cycle is not started, after X minutes the control automatically returns to a cook menu. If Auto-Menu feature is enabled, press the plus or minus button to select a default cook menu that displays after the timer times out. SP-15 COOL TEMP Press the plus or minus button to select a global cool temperature setting. SP-16 PROD PROG EN- TER ALL TIMES FIRST? Press the plus or minus button to select: YES - to step through all the times first, then all temps and then all pressures. NO - to step through Time1, Temp1, Pressure1 and then Time2, Temp2, Pressure2, etc. SP-17 BULK OIL DISPOSE? Press the plus or minus button to select one of three options: NONE - Dispose by draining into a disposal cart or shuttle. REAR HOSE - Dispose by pumping through the rear plumbing connection. SP-17A BULK DISP TANK FULL SIGNAL FRONT HOSE - Dispose by pumping through the front hose connection by pressing and holding the button. INFO: The optional front hose kit must be installed and enabled by a field technician or at the factory in Tech Mode screen T-4A before it displays in Special Programming SP-17. Set to match tank full signal logic of your bulk disposal tank: NONE - Disables tank full signal. Programming 75

90 Menu Display Name Function 24V=FULL - 24V signal on DTF wires means tank is full (do not pump). No signal means it is OK to pump. 24V=OK - 24V signal on DTF wires means it is OK to pump. No signal means the tank is full (do not pump). SP-18 SP-19 SP-20 SP-21 BULK OIL SUPPLY? COOKING: SHOW PSI? CHANGE MGR CODE CHANGE USAGE CODE Press the plus or minus button to select either YES, NO, or YES+BSV to indicate if a bulk oil supply is available for refilling the ATO oil tank and vat with fresh oil. n/a Provides access to change the Manager password code, which is defaulted to 123 from the factory. The manager password code is used to access modes such as Product, Cook, Special Programming, etc. Provides access to change the Reset Usage password code, which is defaulted to 123 from the factory. The Reset Usage password code is used to access the usage statistics, it does not grant any programming privileges. SP-22 CLEAN-OUT TYPE The Clean-Out function supports two different water based clean-out modes, Heated and Cold-Soak. Heated is heated and timed while Cold-Soak is unheated and not timed. KFC software is hard-coded for Cold-Soak only, it cannot be changed. SP-23 CLEAN-OUT TEMP If Heated mode is selected in the SP-22 menu, operators may select a temperature between 40 F 195 F with which to heat the water. Higher temperatures require Personal Protective Equipment (PPE) to prevent burns. If Cold-Soak mode is selected in the SP-22 menu, this setting displays Cold-Soak and can not be changed. Programming SP-24 CLEAN-OUT MINUTES If Heated mode is selected in the SP-22 menu, operators may select a time 1 Min. to 99 Min. The timer starts after the water is heated to the temperature selected in SP-23. The clean cycle time allows the amount of time necessary to scrub the vat and lid before prompting to drain and rinse. If Cold-Soak mode is selected in the SP-22 menu, this setting displays Cold-Soak and can not be changed. 76

91 8.6 Filter Control The Filter Control mode allows the parameters during a filter cycle to be modified for the best results depending on the oil type. Each parameter is grouped into a section that controls a particular settings. See Table 8-3 Filter Settings, page 77. To access the Filter Control menu do the following: 1) Press and hold the menu button until *MAIN* displays. 2) Press the menu button again. The 4. PROG menu displays. 3) Select 4. PROG. 4) Type 123. The 6. FLTR CTRL menu displays. 5) Select 6. FLTR CTRL. 6) Use the left or right arrow to navigate through the options. Table 8-3 Filter Settings Program Code Display Description Quick Filter Settings INFO: The Start-up Mix and the Cook Mode Auto Mix operations are specialized versions of the Quick Filter, and share some of the Quick Filter programmable parameters. For example, both of the Mix operations use the Quick Filter s Max Pump Time setting. For very thin (low viscosity) cooking oils, drain opening setting may need to reduce from the default value and you might need to reduce the drain opening setting from the default value. For 50 Hz systems, or if the control routinely gives up before the pot is refilled, you might need to increase the max pump time from the default value 50 Hz pumps may run more slowly than 60 Hz pumps. These parameters control the Quick Filter operation. The Quick Filter has three basic steps: 1. DROP - Opens the drain and drops the oil level by a certain amount. Depending on settings, may drop the oil level just a few inches during this phase, or could drain the entire pot. 2. FILTER - Runs the filter pump with the drain partially open for a given time, pumping the oil through the filter paper to clean the oil. This operation typically holds a relatively constant oil level in the pot. 3. FILL - Closes the drain fully and runs the filter pump to refill the pot. Watches for a temperature rise on the upper temperature probe (level probe) to indicate that the pot Programming 77

92 Program Code Display Description has refilled. Runs the pump a bit longer to get the last of the oil out of the drain pan, then turns the pump off. FC-1 FILTER TRACKING MODE There are two options, GLOBAL and MIXED MODE. GLOBAL - If selected, continue at FC-1A. MIXED - If selected, skip FC-1A, and then go to Product Programming mode to specify the filter cycles allowance for each individual product. Refer to Chapter 8 Programming, page 65. A new Info button status screen has been added to display how many cook cycles remain before the next auto-filter is activated if Global mode, or to indicate the current accumulated filter usage as a percent, accumulating up toward 100% at which point the next auto-filter is activated if Mixed mode. INFO: The control defaults to Global Mode filtering, with the global Filter After X Cooks parameter set to 1. FC-1A QUICK FILTER: AFTER X COOKS Controls automatic activation of the Quick Filter after the specified number of cook cycles. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. Programming FC-2 QUICK FILTER: DROP OIL: TIME 3. Press X to return to default or previous setting. During the Drop cycle, controls the duration of time the vat drains. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 78

93 Program Code FC-3 Display QUICK FILTER: DROP OIL: DRAIN OPENING Description 3. Press X to return to default or previous setting. During the Drop cycle, controls how far to open the drain valve. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. FC-4 QUICK FILTER: FILTER: TIME At the end of the Drop cycle, controls how long the filter pump runs for the specified filter time. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. FC-5 QUICK FILTER: FILTER: DRAIN POSITION At the end of the Drop cycle, controls how far the drain closes to a partially open position. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. FC-6 QUICK FILTER: FILL: DETECT AT LEVEL PROBE, KEEP PUMPING When refilling the pot, controls how long to keep pumping after the oil initially reaches or splashes on the upper probe and the expected temperature rise is observed. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. Programming 79

94 Program Code FC-7 FC-8 Display QUICK FILTER: NORMAL FILL TIME QUICK FILTER: FILL: NO DE- TECT: MAX PUMP Description 3. Press X to return to default or previous setting. The expected time it takes to refill the vat at the end of a Quick Filter. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. If the fryer pumps for this amount of time during the Fill phase without observing a temperature rise on the upper temperature probe, the control turns the pump off, and asks IS POT FILLED?. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. Daily Filter Settings INFO: In a Daily Filter, a FILL operation can be stopped by the user at any time. For very thin (low viscosity) cooking oils, drain opening setting may need to reduce from the default value and you might need to reduce the drain opening setting from the default value. Programming For 50 Hz systems, or if the control routinely gives up before the pot is refilled, you might need to increase the max pump time from the default value 50 Hz pumps may run more slowly than 60 Hz pumps. FC-9 DAILY FILTER: DROP OIL: TIME During the Drop cycle, controls the duration of time the vat drains. 1. Enter a new value by using the product numbers. 80

95 Program Code FC-10 FC-11 Display DAILY FILTER + POLISH: FILL: DETECT AT LEVEL PROBE, KEEP PUMPING DAILY FILTER: FILL: NO DE- TECT: MAX PUMP Description 2. Press to accept the new value. 3. Press X to return to default or previous setting. When refilling the pot, specifies how long to keep pumping after the oil reaches the upper probe and the expected temperature rise is observed. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. If the fryer pumps for this amount of time during the FILL phase without observing a temperature rise on the upper temperature probe, the control turns the pump off, and asks IS POT FILLED?. If pot is not filled completely, press NO and the pump attempts to fill further. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. Polish Settings INFO: For very thin (low viscosity) cooking oils, drain opening setting may need to reduce from the default value and you might need to reduce the drain opening setting from the default value. For 50 Hz systems, or if the control routinely gives up before the pot is refilled, you might need to increase the max pump time from the default value 50 Hz pumps may run more slowly than 60 Hz pumps. Programming 81

96 Program Code Display Description FC-12 POLISH: DROP OIL: TIME During the Drop cycle, controls the duration of time the vat drains. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. FC-13 POLISH: DROP OIL: DRAIN OPENING During the Drop cycle, controls how far to open the drain valve. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. FC-14 POLISH: FILTER: TIME At the end of the Drop cycle, controls how long the filter pump runs for the specified filter time. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. FC-15 POLISH: FILTER: DRAIN OPENING At the end of the Drop cycle, controls how far the drain closes to a partially open position. Programming 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. FC-16 POLISH: NORMAL FILL TIME The expected time it takes to refill the vat at the end of a Polish operation. When refilling the vat, if the fryer pumps for one and a half 82

97 Program Code FC-17 Display POLISH: FILL: NO DETECT: MAX PUMP Description times this expected time, the SLOW FILLING warning is activated, alerting that the fryer is pumping more slowly than expected. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. If the fryer pumps for this amount of time during the FILL phase without observing a temperature rise on the upper temperature probe, the control turns the pump off, and asks IS POT FILLED?. If pot is not filled completely, press NO and the pump will attempt to fill further. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. Auto Top Off Settings INFO: If X pulses of oil have not brought the level up, the control assumes that the oil tank is empty that no oil is being pumped into the pot and displays FILL OIL TANK. If the fryer is configured to use a Bulk Oil Supply system, the message displayed is CHECK BULK OIL SUPPLY rather than FILL OIL TANK. In this case, it is possible that the remote bulk supply tank is empty, that the bulk supply plumbing connection is not connected to the fryer, or that the bulk supply electrical connection is not connected. FC-18 AUTO TOP OFF: ENABLED? Enables or disables all Auto Top Off (ATO) operations. 1. Press the + or - button to select either YES or NO. Disabling the Auto Top Off feature would normally be done only if the top off system itself has failed, in order to avoid the FILL OIL Programming 83

98 Program Code Display Description TANK messages that occur if the fryer doesn t detect oil at the proper level after 3 attempts. FC-19 AUTO TOP OFF: PUMP TIME Specifies how long the ATO pump runs for each individual ATO pulse. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. This setting may be manually adjusted as needed. Ideally, each ATO pulse pumps about 1/8 (3.175 mm) to 3/16 (5 mm) of fresh oil into the pot. FC-20 AUTO TOP OFF: REPEAT Specifies how long the control waits before assessing the oil level and generating a second ATO pulse if the oil level is still low. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. Programming FC-21 AUTO TOP OFF: AFTER X ATTEMPTS, CHECK ATO After each ATO pulse, the control monitors the level probe temperature to see if the oil has been brought up to the proper level. If not, a second ATO pulse is given. After a certain number of pulses, as specified by this setting, if the oil level still has not been brought up to the proper level, the control beeps and displays FILL OIL TANK. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 84

99 Program Code FC-22 Display COOK MODE - FORCED ATO CHECK AFTER X COOKS Description 3. Press X to return to default or previous setting. Controls the number of cook cycles before forcing a check of the ATO. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. Start-up Mode Settings FC-23 START-UP: NEEDED IF TEMP < X If the oil temperature is below 215 F when the fryer is turned on, the fryer always executes a Melt Mode regardless of the Start-up Needed setting. Sets temperature base to initiate a Start-up. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. Phase 2 of the morning startup procedure is to execute the Start-up Mix operation: drop all of the oil into the drain pan, filter it for a short time, and pump it back into the vat. This feature is important in thermally mixing the oil to eliminate cold spots and eliminate the milky oil in the bottom of the pot. FC-24 START-UP MIX: ENABLED? There are two choices; Mix or Daily. Mix controls whether or not the Mix operation is performed automatically or manually as part of a morning start-up. Daily replaces the Mix with a Daily filter. Some operators may prefer performing a daily filter in the morning instead of at night. Daily filter is manual only. The unit prompts for a Daily filter during Start-up if selected. Programming 85

100 Program Code FC-25 FC-26 Display START-UP MIX: PRE-HEAT MAX TEMP START-UP MIX: DROP OIL: TIME Description Press the + or - button to select either Mix or Daily, and if Mix, YES or NO to run automatically. The Start-up Mix procedure consists of two steps: 1. Heat up the oil to the Mix Preheat temperature and 2. Drop the oil, filter, and refill the pot. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. Controls the time duration of the draining of the pot. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. FC-27 START-UP MIX: FILTER: TIME This setting specifies how long the oil should be circulated during the FILTER phase of the Start-up Mix. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. Programming FC-28 START-UP MIX: NORMAL FILL TIME 3. Press X to return to default or previous setting. The expected time it takes to refill the vat at the end of a Start-up Mix operation. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 86

101 Program Code FC-29 FC-30 Display START-UP MIX: FILL: NO DE- TECT: MAX PUMP START-UP ATO CHECK: ENABLED? Description 3. Press X to return to default or previous setting. If the fryer pumps for this amount of time during the FILL phase without observing a temperature rise on the upper temperature probe, the control turns the pump off, and asks IS POT FILLED?. If pot is not filled completely, press NO and the pump will attempt to fill further. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. Specifies whether or not the ATO (Auto Top Off) Check, the third step of the Start-up Mode, is enabled. FC-31 START-UP ATO CHECK: PRE- HEAT MAX TEMP Press the + or - button to select either YES or NO. The Start-up Auto Polish procedure consists of two steps: 1. Heat up to the Polish Preheat temperature. 2. Drop the oil, filter (for a long time), and refill the pot. Phase 4 of the morning startup procedure is to execute the Start-up Auto Polish: drop the oil into the drain pan, filter it for a long time, and pump it back into the pot. This feature is important in cleaning the oil and restoring clarity to it. Filter powder should be added to the drain pan in order for the Polish operation to be most effective. FC-32 FC-33 START-UP POLISH: ENABLED? START-UP POLISH: PRE- HEAT MAX TEMP Henny Penny recommends enabling the Start-up Polish to prolong the life of the oil. This adds time to the Start-up process. Press the + or - button to select either YES or NO. The Start-up Auto Polish procedure consists of two steps: 1. Heat up the Polish Preheat Programming 87

102 Program Code Display Description temperature. 2. Drop the oil, filter (for a long time), and refill the pot. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. Cook Mode Auto Mix Settings The Cook Mode Auto Mix is a modified Quick Filter operation. It consists of three phases: 1. Drop (drop the oil level). 2. Filter (circulate it through the filter paper). 3. Fill (pump the oil back into the pot). FC-34 COOK MODE AUTO MIX: ENABLED? This setting determines whether or not the Cook Mode Auto Mix feature is enabled. Press the + or - button to select either YES or NO. FC-35 COOK MODE AUTO MIX: DROP OIL: TIME Controls the time duration of the draining of the pot. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. Programming FC-36 COOK MODE AUTO MIX: FIL- TER: TIME Controls how long the filter pump runs for the specified filter time. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. 88

103 Program Code Display Description FC-37 COOK MODE AUTO MIX: NORMAL FILL TIME The expected time it takes to refill the vat at the end of an auto mix operation. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. FC-38 COOK MODE AUTO MIX: FILL: NO DETECT: MAX PUMP If the fryer pumps for this amount of time during the FILL phase without observing a temperature rise on the upper temperature probe, the control turns the pump off, and asks IS POT FILLED?. If pot is not filled completely, press NO and the pump will attempt to fill further. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. FC-39 COOK MODE AUTO MIX: DE- SIRED BOTTOM TEMP The purpose of the Cook Mode Auto Mix operation is to attempt to keep the bottom of the pot hot enough that crumbs don t stick. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. FC-40 COOK MODE AUTO MIX: MIN REQUIRED OIL TEMP 3. Press X to return to default or previous setting. This is the minimum oil temperature required in order to activate an Auto Mix operation. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. Programming 89

104 Program Code FC-41 FC-42 Display COOK MODE AUTO MIX: MIN REPEAT COOK MODE TIMED AUTO MIX, IF BAD BOTTOM PROBE Description 3. Press X to return to default or previous setting. This setting controls how often a bottom-temperature triggered Auto Mix can repeat. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. This option is used only if the temperature probe on the bottom of the pot has failed or is disconnected. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. Dispose Settings FC-43 DISPOSE: DROP OIL: DRAIN OPENING This setting specifies the drain opening to be used when draining the oil to a disposal cart, shuttle, or bucket for disposal. (Does not apply to Bulk Dispose operations.) 1. Enter a new value by using the product numbers. 2. Press to accept the new value. Programming Miscellaneous Settings 3. Press X to return to default or previous setting. 90

105 Program Code FC-44 Display ALWAYS ASK, IS POT FILLED? Description This option can be engaged to always ask at the end of each Quick Filter, Auto Mix, and Polish operation, if the pot is filled. Normally, the control asks IS POT FILLED? only if it has pumped for a long time attempting to fill the pot, but no temperature rise was observed on the upper temperature probe. FC-45 ANY FILL: NOT FILLED, EX- TRA PUMP TIME Press the + or - button to select either YES or NO. When refilling the pot at the end of a Quick Filter, Auto Mix, or Polish operation, the control closes the drain and runs the pump until a suitable temperature rise is observed on the upper temperature probe (the level probe). If no temperature rise is seen after pumping for a reasonable maximum pumping time, the control stops, turns the pump off, and asks IS POT FILLED?. 1. Enter a new value by using the product numbers. 2. Press to accept the new value. 3. Press X to return to default or previous setting. 8.7 Tech Mode Menu To access the Tech Mode menu from the Program menu, press the 7. Tech Mode button and then type the code Refer to4.6 Menu Structure, page 19. Menu Item (Mode) Display Table 8-4 Tech Mode Menu Function Function T-1 SOFTWARE ID S Press and hold lower-left button to view software release level. Shows the active version of software in the middle display. T-2 METADATA Displays information about the file that was used to flash the software into the control board, includes: Programming 91

106 Menu Item (Mode) Display Function including the ID of the file, date it was created, original file size, original file name, the version number of the metadata information, the authentication (checksum), and the board assemblies that the software is compatible with. T-3 FRYER TYPE Shows what type of fryer (pressure or open) in the middle display. To change the fryer type, press the illuminated lower-left button to change from PRESSURE to OPEN. The model type will change in the middle display. T-4 FRYER HAS SEL VALVE NO- The unit is not equipped with a selector valve. YES - The unit is equipped with a selector valve. If incorrectly labeled, use the plus or minus button to change. T-4A FRONT DISPOSE KIT INSTALLED? An optional kit is available to support a front dispose connection, where a hose is connected to a quick disconnect fitting at the front of the fryer, and bulk dispose operations pump directly into a portable disposal cart. T-5 FRYER SERIAL NUMBER This fryer s serial number is programmed into the control so that it can be included in USB reports and can be used when naming data log files. T-6 PUSH BUTTON TEST This section tests all the button to confirm all are working correctly. Press any of the non-illuminated button to enter the test mode. The screen will return to normal operation after 3 seconds of no activity. T-7 DISPLAY TEST This section tests all of the LED and display lights. Press the illuminated button next to the type of test listed on the display. Press and hold the button of the LED test to test all the lights on the buttons. Press and release the button next to the display test options to circulate through the different sections of the display. Programming T-8 AUDIO TEST Press the button next to start the Audio volume test. Press and hold the button next to Hold to test the current volume. T-9 LVL TEMP OFFSET ADJ Shows the current temperature of the oil at the level probe. To adjust the temperature. press and hold the button next to Temp With the button held, press the plus or minus button to adjust the temperature. To adjust the offset, press and hold the button next to the OFST With the button held, press the plus or minus button to adjust the offset. 92

107 Menu Item (Mode) Display Function T-10 MAIN TEMP OFFSET ADJ T-11 BOTTOM TMP OFFSET ADJ Shows the current main temperature of the oil. To adjust the temperature, press and hold the button next to TEMP With the button held, press the plus or minus button to adjust the temperature. To adjust the offset, press and hold the button next to OFST With the button held, press the plus or minus button to adjust the offset. Shows the current temperature of the oil at the bottom probe. To adjust the temperature, press and hold the button next to TEMP With the button held, press the plus or minus button to adjust the temperature. To adjust the offset, press and hold the button next to OFST With the button held, press the plus or minus button to adjust the offset. T-12 SPARE TMP OFFSET ADJ T-13 CPU TEMP OFFSET ADJ Accesses a spare temperature probe input. To adjust the temperature, press and hold the button next to TEMP With the button held, press the plus or minus button to adjust the temperature. To adjust the offset, press and hold the button next to the OFST With the button held, press the plus or minus button to adjust the offset. This displays the current CPU temperature offset. To adjust the temperature, press and hold the button next to Temp With the button held, press the plus or minus button to adjust the temperature. To adjust the offset, press and hold the button next to OFST With the button held, press the plus or minus button to adjust the offset. T-14 INPUTS-1 A H D S F P M shows in the middle display. A - Power Switch. H - High Limit. D- Drain Switch Jumper. S - Power Switch. F - Fan Switch Jumper. P - Not in use at this time. M - Not in use at this time. check - signal present. - signal not present. T-15 INPUTS-2 24dc - 24 DC Supply. Pan - Filter Drain Pan. Lid - Lid Liner Pin. OK - lid pin is down (not under pressure). Flashing PR - lid pin is raised (under pressure) check - active. - inactive. T-16 INPUTS-3 DTF, HDP, AFR show in the middle display. DTF - Discard Tank Full. check - Tank is full; cannot dispose oil to tank. HDP - High Dispose Pressure check - Dispose pumping caused high pressure. AFR - ATO Fill Request. check - Switch is asking to pump Bulk Supply Oil to refill the ATO tank. Programming 93

108 Menu Item (Mode) Display Function T-17 PRESSURE INPUTS This section shows the current psi of the lid. If OK is on the display, the lid is safe to open. Otherwise, PR; flashes showing lid is under pressure. The bottom display reads Lid Pin;. If OK is on the display, the lid pin is down. Other wise, PR flashes showing the pin is raised (under pressure). T-17A PUMPING PRESSURE This section shows the current pumping pressure in psi. T-18 OUTPUTS Press the illuminated button next to the feature to test. Pri - Primary Contactor. Ht - Heat (regulating) Contactor. Pr - Pressure Solenoid. * - On. - - Off. T-19 DRN VALVE Be sure drain pan is in place before testing drain valve. This section tests the drain valve functions. - Shows next to the drain valve current state. Par - Partially open. Stp - Forced stop. Opn - Fully open. At - Where the drain valve stopped from Max open position may be as high as 25 or 50. Cls - Fully closed. T-20 SEL VALVE FWD/REV This section tests the selector valve rotation position. Cst - Coast counts how much the motor coasts after being turned off (11 = typical). Stp - Stop the selector valve rotation. Fwd - Press to rotate the selector valve forward. Rev - Press to rotate the selector valve in reverse. Enc (encoder) - Shows the position count, 0 to 999. When running, top line shows time of each revolution. T-21 SEL VALVE PORTS This section tests the positioning of each port on the selector valve. P0 - At pot. P1 - At dispose (rear dispose) P2- At FDI (front dispose) Enc - Encoder position. FAIL - Selector valve does not function properly. T-22 PUMPS Press the illuminated button next to the function to start test * - On - - Off Fltr - Filter pump ATO- JIB pump (optional) Drn C - Drain valve (c - closed, o - open) Programming T-23 OPS/QPM SYSTEM ENABLED? This section shows if the unit is equipped with a radio system. To change the option press the plus or minus button to select YES or NO T-24 RADIO COM (Zigbee) If the control is equipped with an OPS/QPM ZigBee radio module, and it has been enabled (step T-23 or SP-4), this test mode displays information received from the radio module via the wired connection. If the OPS System is disabled (see previous step), this step simply displays ZigBee IS -OFF- 94

109 Menu Item (Mode) Display Function T-25 ANALOG CHANNELS This test mode is available to display the current lowlevel analog status of any of the analog inputs on the primary Analog to Digital converter chip inside the control. T-26 HEAT CTRL This test mode has very specialized and very limited use. It displays information about the heating algorithm and its performance, and can be useful when tuning the heating algorithm for a brand new fryer type. T-27 ALLOW LID OPEN n/a T-28 LID LINER PIN -MUST- ACTUATE T-29 AFTER COOK, PRES- SURE STUCK ON GIVES ERROR T-30 AUTO-CYCLE PRES- SURE SOLENOID? T-31 BLOCKED DRAIN AUTO-REV RETRIES n/a n/a n/a The control gets a feedback signal from the motorized drain valve when it is at the fully open and fully closed positions. If the control is commanding the drain valve to close, but it doesn t see the closed feedback signal within a reasonable time, it presumes that maybe a brush has been left in the open drain valve and that is preventing the valve from closing. In response, the control automatically opens the drain valve back up, sounds a sequence of fast beeps, and displays Drain Blocked for a few seconds, giving the user time to remove the brush. After a short delay, the control automatically tries to close the drain valve again. T-32 ATO DELTA: -FULL- The auto-topoff (ATO) oil level detection system monitors the temperature difference between the main probe (just above the heating elements) and the level probe (located at the desired oil fill level). In static, noncooking situations, the level probe, high in the pot, is generally cooler than the main probe, even when the pot is properly filled and both probes are immersed in the oil (the oil at the top of the pot radiates a lot of its heat, and conducts heat away, into the air). T-33 ATO DELTA: -LOW- The auto-topoff (ATO) oil level detection system monitors the temperature difference between the main probe (just above the heating elements) and the level probe (located at the desired oil fill level). In static noncooking situations, the level probe high in the pot is Programming 95

110 Menu Item (Mode) Display Function generally cooler than the main probe even when the pot is properly filled and both are immersed in the oil. T-34 QUICK FLTR: FILL TO LVL PROBE - TEMP RISE T-35 DAILY+POL: FILL TO LVL PROBE - TEMP RISE When refilling the pot after a filter operation, the control monitors the upper temperature probe (the level probe, at the oil fill line) and looks for a temperature rise there that indicates the oil has refilled high enough to reach or splash on that probe. When refilling the pot after a filter operation, the control monitors the upper temperature probe (the level probe, at the oil fill line) and looks for a temperature rise there that indicates the oil has refilled high enough to reach or splash on that probe. T-36 ANY FILL: LVL PROBE MIN DETECT How the control monitors the level probe for a temperature rise when refilling the pot is described in the details of step T-34. This T-36 parameter specifies a minimum reasonable filling time for that temperature rise to be trusted. T-37 CHANGE TECH CODE The default Tech Mode password can be changed by the user. This password is used for entry to Tech Mode and Stats Mode. It is recommended that this password not be changed except under extreme circumstances, as a service technician visiting the store to service the fryer would probably not know the new password and would not be able to access Tech Mode. T-38 TOTAL INIT Press and hold the button next to hold on the display to initialize the control board. Programming 96

111 Chapter 9 Troubleshooting 9.1 Troubleshooting Guide NOTICE: More detailed troubleshooting information is available in the Technical Manual, available at www. hennypenny. com, or or Table 9-1 Troubleshooting Guide Problem Cause Correction Power switch is on but the fryer is completely inoperative. Oil not heating. Foaming or boiling over. Open circuit. High temperature limit tripped. Some customers choose not to use oil stabilizers which can cause foaming and boilover. See boil-over chart on fryer and Boil-Over Prevention section of Operator s Manual. Fryer plugged in. Check breaker or fuse at wall. Check circuit breakers between control panel and ATO tank. Reset high temperature limit. Refer to 3.1 Operating Components in the Operator s Manual. Product with excessive ice crystals should be dipped once quickly then removed from the fryer to allow ice crystals to melt and excessive water to evaporate. Then place the product back into the fryer and cook normally. Refer to 2.7 Boil-Over Prevention in the Operator s Manual. Oil not draining. Drain valve clogged. Push cleaning rod through open drain valve. Filter motor won t run. 9.2 Error Codes Motor overheated. Reset motor. Refer to Filter Pump Motor Protector - Manual Reset section of Operator s Manual. In the event of a system failure the control board displays an error message. These messages are coded as E which represents an error, a number designation and error message, such as E-4 CPU TO HOT. Also, a constant tone sounds. To silence the tone, press any of the product buttons. Use the following table to interpret and correct an error code. Troubleshooting 97

112 Table 9-2 Error Codes Error Cause Correction E-1 LOW OIL IN POT E-4 CPU TOO HOT E-5 OIL TOO HOT E-6A MAIN TEMP PROBE FAILED (Open Circuit) The top heating element where the probe is located is getting hotter than it would if the element were submerged in oil. Control board overheating. Oil overheating. Temperature probe failure. If the Protection Probe monitoring function determines that the oil level is too low below the main probe it generates an E-1 error code and displays the message LOW OIL IN POT!, CHECK OIL LEVEL. Turn the switch to off position, then turn the switch back to on. if E-4 continues to display, the board is getting too hot. Check for signs of overheating behind the control panel. Once the panel cools down the controls should return to normal operation. If the E-4 error persists, replace the control. Turn the switch to off position, then turn the switch back to on. If E-5 continues to display, the heating circuits and temperature probe should be checked. Once the unit cools down, the controls should return to normal operation. If the E-5 error persists, replace the control. Turn the switch to off position, then turn the switch back to on. If E-6 continues to display, the temperature probe should be checked. Once the temperature probe is repaired, or replaced, the controls should return to normal operation. If the E-6 error persists, replace the control. Troubleshooting E-6B MAIN TEMP PROBE FAILED (Shorted) E-10 High limit tripped (Software prior to version 1.60). Check the error log to find out the vat temperature at the time the high limit tripped. If this temperature was very low, this may be a sign that the vat was turned on with low or no oil. If this was the case, fill the pot with oil and reset the high limit. If the trip temperature was several degrees above the oil setpoint temperature, test for a sticking contactor and replace if faulty. If the high limit tripped at an oil temperature, inspect the high 98

113 Error Cause Correction limit thermocouples for carbon build up and clean if necessary. If no carbon found, see 7.8 High Limit and Module Inspection, page 53and 11.6 High Limit Thermocouples Replacement, page 118. E-10A HIGH LIM- IT TRIPPED High limit tripped while vat main probe temperature was at or above 300 F. Check the error log to find out the vat temperature at the time the high limit tripped. If this was several degrees above the oil setpoint temperature, test for a sticking contactor and replace if faulty. If the trip temperature was near the oil setpoint temperature, inspect the high limit thermocouples for carbon build up and clean if necessary. If no carbon found, see 7.8 High Limit and Module Inspection, page 53and 11.6 High Limit Thermocouples Replacement, page 118. E-10B HIGH LIM- IT TRIPPED High limit tripped while vat main probe temperature was below 300 F. Check the error log to find out the vat temperature at the time the high limit tripped. If this temperature was very low, this may be a sign that the vat was turned on with low or no oil. If this was the case, fill the pot with oil and reset the high limit. If the high limit tripped at a higher temperature, inspect the high limit thermocouples for carbon build up and clean if necessary. If no carbon found, see 7.8 High Limit and Module Inspection, page 53and 11.6 High Limit Thermocouples Replacement, page 118. E-10C HIGH LIM- IT TRIPPED E-10D HIGH LIM- IT TRIPPED High limit tripped while cooking (Not simply in cook mode, but with cook cycle running). High limit tripped less than 5 minutes after fryer was performing an Auto-Filter or Quick Filter and the control returned to cook mode Check the error log to find out the vat temperature at the time the high limit tripped. If this was several degrees above the oil setpoint temperature, test for a sticking contactor and replace if faulty. If the trip temperature was near the oil setpoint temperature, inspect the high limit thermocouples for carbon build up and clean if necessary. If no carbon found, see 7.8 High Limit and Module Inspection, page 53and 11.6 High Limit Thermocouples Replacement, page 118. Check the error log to find out the vat temperature at the time the high limit tripped. If this was several degrees above the oil setpoint temperature, test for a sticking contactor and replace if faulty. If the trip temperature was near the oil setpoint temperature, inspect the high limit thermocouples for carbon build up and clean if necessary. If no carbon found, see 7.8 High Troubleshooting 99

114 Error Cause Correction on its own after detecting that the oil was pumped up (based on temperature rise on level probe). Limit and Module Inspection, page 53and 11.6 High Limit Thermocouples Replacement, page 118. E-10F HIGH LIM- IT TRIPPED High limit tripped while filtering (including Auto-Filter, Daily Filter, Polish, Dispose, Drain to Pan, Fill from Pan, etc.). Check the error log to find out the vat temperature at the time the high limit tripped. If this was several degrees above the oil setpoint temperature, test for a sticking contactor and replace if faulty. If the trip temperature was near the oil setpoint temperature, inspect the high limit thermocouples for carbon build up and clean if necessary. If no carbon found, see 7.8 High Limit and Module Inspection, page 53and 11.6 High Limit Thermocouples Replacement, page 118. E-10M HIGH LIM- IT TRIPPED High limit tripped while fryer was in Melt Mode. Check the error log to find out the vat temperature at the time the high limit tripped. If this temperature was very low, this may be a sign that the vat was turned on with low or no oil. If this was the case, fill the pot with oil and reset the high limit. If the high limit tripped at a higher temperature, inspect the high limit thermocouples for carbon build up and clean if necessary. If no carbon found, see 7.8 High Limit and Module Inspection, page 53and 11.6 High Limit Thermocouples Replacement, page 118. Troubleshooting E-10S HIGH LIM- IT TRIPPED E-10Y HIGH LIM- IT TRIPPED High limit tripped while vat was in Start-up Mode (not including Melt mode), but not while it was executing one of the filter operations. High limit tripped less than 5 minutes after user responded Check the error log to find out the vat temperature at the time the high limit tripped. If this temperature was very low, this may be a sign that the vat was turned on with low or no oil. If this was the case, fill the pot with oil and reset the high limit. If the high limit tripped at a higher temperature, inspect the high limit thermocouples for carbon build up and clean if necessary. If no carbon found, see 7.8 High Limit and Module Inspection, page 53and 11.6 High Limit Thermocouples Replacement, page 118. Check the error log to find out the vat temperature at the time the high limit tripped. If this temperature was very low, this may be a sign that the vat was turned on with low or no oil. If this was the case, fill the pot with 100

115 Error Cause Correction YES to, Is Pot Filled? question. oil and reset the high limit. If the high limit tripped at a higher temperature, inspect the high limit thermocouples for carbon build up and clean if necessary. If no carbon found, see 7.8 High Limit and Module Inspection, page 53and 11.6 High Limit Thermocouples Replacement, page 118. E-15C DRAIN VALVE ERROR The control energized the drain valve to close it, and waited a reasonable amount of time, but didn t see the expected feedback signal that would have confirmed that the drain valve was fully closed. Check the drain valve for obstruction. Carefully remove any obstruction found. If no obstruction, check to make sure both connections to the drain valve are plugged in securely. If connections are secure, operate the drain valve using the drain valve test in tech mode. If no drain valve movement, test to make sure the drain valve is getting 24 VDC from control board when testing both directions (open and closed) from connector P9 pins 3 & 4. If voltage is present and no movement, replace drain valve motor. If no DC voltage, replace control board. E-15P DRAIN VALVE ERROR The control energized the drain valve to open it, and waited a reasonable amount of time, but didn t see the expected feedback. signal that would have confirmed that the drain valve was fully open. Check to make sure both connections to the drain valve are plugged in securely. If connections are secure, operate the drain valve using the drain valve test in tech mode. If no drain valve movement, test to make sure the drain valve is getting 24 VDC from control board when testing both directions (open and closed) from connector P9 pins 3 and 4. If voltage is present and no movement, replace drain valve motor. If no DC voltage, replace control board. E-18A LE- VEL SEN- SOR FAILED (Open Circuit) E-18B LE- VEL SEN- SOR FAILED (Shorted) The oil level probe has failed. Press button to keep using the fryer. Error repeats every four hours until fixed. If circuit is open, check connection. Replace probe. Troubleshooting 101

116 Error Cause Correction E-19 PRO- TECTION PROBE FAILED A setting in Tech Mode (T-40) specifies whether or not the fryer is equipped with a protection probe system. If the T-40 option is set to YES, and the control does not detect a valid reading on the protection probe input, an E-19 error is generated. Replace the protection probe. Once the error code is acknowledged, the E-19 message goes away and normal operation resumes without the benefit of the protection probe feature. If the protection probe input is in a continuously failed state, the E-19 error repeats every 4 hours. If this E-19 error occurs in a fryer that does not have and is not supposed to have a protection probe installed, access Tech Mode and change the T- 40 option to NO. E-41P-1- LOST System data lost. Both the RAM copy and stored copy of the settings have been lost. Settings are reset to default. Replace control board if occurs repeatedly. E-41 SYS- TEM DATA LOST System data lost. Both the RAM copy and stored copy of the settings have been lost. Settings are reset to default. Replace control board if occurs repeatedly. E-46C IN- TERNAL SD MEM ERR Issue with microsd chip. Check to ensure chip is not ejected from slot. Troubleshooting E-46W DATA SAVE FAILED E-47 ANA- LOG SYS- TEM OR 12 VOLT FAILED Unable to communicate and save data to the microsd chip. Corrupt file. Problem reading the A-to-D Analog to Digital converter inputs. Replace control board if occurs repeatedly. Check 12 VDC and 5 VDC analog power supplies Unplug pressure transducer at back of control. Unplug filter pump relay at back of control. Replace control board. 102

117 Error Cause Correction E-48 IN- PUT SYS- TEM ERROR Failure of the CPU board. Replace control board. E-54C MAIN TEMP CIR- CUIT FAILURE Fault on the CPU board. Initialize the CPU board. Replace control board E-54D MAIN TEMP DSC ERROR Fault on the CPU board. Initialize the CPU board. Replace control board E-70A FAN JUMP MISSING Jumper wire is loose or missing from 15 pin connector. Check connector for loose connection. E-70B PWR SWITCH OR WIRES FAILED Short in wires/ loose connection. Power switch may be faulty. Check connections of all four wires on the power switch Replace power switch. E-70C DRN JUM- PER MISSING Loose connection on the 15 pin connector. Check connection. E-82 SE- LECTOR VALVE FAILURE E-93 24V DC SUPPLY The selector valve failed calibration or not responding. 2nd transformer disconnected from control. Short in drain motor or selector valve motor. Check motor, encoder or wiring. If unit is not equipped with a selector valve and gives this error: check settings in to confirm settings are correct. Check transformer plug on back of control. Check wire connections on 2nd transformer. Test motors. Troubleshooting 103

118 Troubleshooting 104

119 Chapter 10 Software Updates Periodically the software is updated with enhancements, menu changes or must be reloaded such as when a control board is replaced or updated with a newer model control. Use the following procedures to reload the software Software Updates Control Board Updates The control board is operated by an onboard Micro SD card, which is loaded with HP software during the factory programming process and/or installation; it occasionally requires an update. The software on a control board must be loaded from a USB drive. The file type used for loading software is an.hpf (Henny Penny Flash) file. All. hpf files are encrypted and are checksum protected, in order to prevent accidental or malicious changes to the official HP software. In addition, the boot-loader program on the control board allows selection of only the.hpf files that are designed for that specific unit s control assembly. This prevents accidental loading of say a holding cabinet in to a pressure fryer control, or similar mistake USB Port Overview Disconnect the power or electrical shock will occur. Lowering the control board exposes the technician to 240 VAC electricity inside the fryer. The external USB port on the front of the unit is connected to an internal USB port on the control board with a short wiring harness. If the external USB port fails, access and use the internal USB port by lowering the control board from the unit to gain access to the internal USB port. Refer to 11.4 USB Port Replacement, page SanDisk USB Flash Drive Two SanDisk brand USB flash drives with plastic tips, 2 to 8 GB of storage space and formatted with FAT 32 are shipping with each unit. One is zip tied externally to the front of the unit and the second internally to the back of the control board. Each contains the most current version.hpf file for the unit based on ship date. If the customer s USB drives are missing or outdated, refer to Version Updates, page 106. INFO: It is recommended that before performing a service call, technicians check for and download the latest version of the software, and then update the unit while on site. Updated versions contain the latest customer requested features and fixes. Software Updates 105

120 Version Updates Current versions of the software are maintained on the HP Extranet by unit model and software version. Because the customer s on site USB flash drive may be outdated. Download the newest version of the software to an approved plastic tipped USB flash drive before performing a service call. Refer to SanDisk USB Flash Drive, page 105and Access the Extranet, page 106to download the most current version of software Access the Extranet The better the quality of ISP service the quicker the access to the Extranet. Always use a non-public, secure connection to the Extranet to prevent non-authorized access. Access the HP Extranet by doing the following: 1) From a Internet connected laptop, navigate to MyHennyPenny. 2) Scroll down to the Quick Links on the right side of the page. The Extranet- Distributor Network link displays. 3) Click the Extranet-Distributor Network link. Wait, a login displays. 4) Type your HP assigned address in the address text box and then your user defined password in the Password text box. 5) Click the LOGIN button. The HP Extranet home page displays. INFO: Add the Extranet to the Favorite list in the browser of the laptop for ease of future access. Software Updates Locate and Download the Latest Version of Software Download the latest.hpf software by doing the following: 1) In the upper right corner of the HP Extranet home page, type Software Update in the search box, and then press Enter. All Documents displays in the left navigation bar. 2) Click the Software Update link from the All Document menu list. A list of updates displays in the center navigation bar. INFO: Always select the latest version of software from the list unless directed otherwise by HP Technical Support. 3) Scroll through the list and locate the latest.hpf file and then click on the associated READ MORE> link. A pop-up window displays asking if you want to save the file. If not, ensure pop-up blockers are disabled. INFO: Optionally download the file by right-clicking the READ MORE> link and selecting the Save Target As option. 4) Click Save and save the file to the laptop using the default file name. INFO: Do not change the file name, it is used during the reflashing process and to differentiate customer specific information. 5) Move the file to an approved plastic tipped USB flash drive. Refer to SanDisk USB Flash Drive, page

121 Loading the Software The control board is operated by an onboard Micro SD card loaded with HP software during the factory programming process or installation. The software can be reloaded from a plastic tipped USB flash drive. Perform a software reload by doing the following: 1) Begin with the control in -OFF- mode, and the filter drain pan in place. 2) Insert the USB flash drive in to the external USB port on the control board. 3) Press and hold the Main Menu button until *MAIN* displays. Refer to 4.2 Controls and Indicators, page 17. 4) Select 3. USB/DATA from the Main Menu. Additional menus display. Refer to 4.5 Main Menu, page 18. 5) Select USB Menu page 2. Additional menus display. 6) Select 4. REFLASH SW. Additional menus display. 7) Select 1. Update. Files display. 8) Locate and select the.hpf file. Are You Sure displays. 9) Select Y. 10)Wait. The control saves a copy of the current software, erases program memory, flashes in new software, and then reboots back to -OFF-. 11)Remove the USB drive. INFO: E-41 (data lost) and other errors are common Download a Report Use the following procedure to download a report. 1) Begin with the control in -OFF- mode, and the filter drain pan in place. 2) Insert the USB flash drive in to the external USB port on the control board. 3) Press and hold the Main Menu button until *MAIN* displays. Refer to 4.2 Controls and Indicators, page 17. 4) Select 3. USB/DATA from the Main Menu. Additional menus display. Refer to 4.5 Main Menu, page 18. 5) Select 1. REPORTS. Additional menus display. 6) Select Print Report. Additional menus display. 7) Select Print. Once the print process is complete, REMOVE USB displays. 8) Select REMOVE USB. 9) Wait. OK to Remove displays. 10)Remove the USB drive. 11)Select X. -OFF- mode displays. Software Updates 107

122 Software Updates 108

123 Chapter 11 Repair and Replacement Procedures This section provides checkout and replacement procedures, for various parts of the fryer Maintenance Hints Do not move the fryer with hot oil in the vat or filter pan. Severe burns can result from splashing hot oil. NOTICE: A multimeter can help you to check the electric components: When the manual refers to the circuit being closed, the multimeter should read zero unless otherwise noted. When the manual refers to the circuit being open, the multimeter should read infinity Control Board Replacement Disconnect the power or electrical shock will occur. Lowering the control board exposes the technician to 240 VAC electricity inside the fryer. 1. Use the Phillips head screwdriver to remove the two screws securing the control board to the front shroud. 2. Press in on the bottom of the board, and rotate the panel down until it rests on the shroud. 3. Disconnect all the connectors on the back of the control board. Repair and Replacement Procedures 109

124 4. Use a 3/8 inch nut-driver or socket and remove the nut securing the ground wire to the control board. 5. Remove old control board. 6. Place new control board on to the unit with the tab inserted in to the slot. Let the control board rest on the shroud. 7. Use a 3/8 inch nut-driver or socket and reconnect the nut securing the ground wire to the control board. 8. Reconnect all the connectors on the back of the control board. Repair and Replacement Procedures 9. Use the Phillips head screwdriver to reinstall the two screws securing the control board to the front shroud. 110

125 11.3 Power Switch Replacement Disconnect the power or electrical shock will occur. Lowering the control board exposes the technician to 240 VAC electricity inside the fryer. 1. Perform the removal procedure from 11.2 Control Board Replacement, page Use a flat-blade screwdriver to press down on the locking tabs. 3. Pull the old switch out of the shroud, and then disconnect the wires. 4. Attach the wires to the new switch, and then slide new power switch into the shroud. 5. Perform the installation procedure from 11.2 Control Board Replacement, page USB Port Replacement 6. Test the operation. The USB port is typically replaced after a software update fails with the assumption the port is bad. There are multiple failure points in the circuit that can cause the update process to fail. Before replacing the external USB port attempt a software update using the internal USB port located on the control board. A short jumper wire connects the external USB port to the internal USB port, ensure it s connected and intact. Corrupted, out of date or incorrect versions of the files on the USB drive can also cause an update failure. 1. Remove the USB cover cap. 2. Use an adjustable wrench to remove the locking nut. 3. Perform the removal procedure from 11.2 Control Board Replacement, page 109. Repair and Replacement Procedures 111

126 4. Disconnect the USB plug from the receiver on the back of the control board. 5. Remove the old USB port assembly from the hole in the control board. 6. Install the new USB port assembly in the hole in the control board. 7. Use one adjustable wrench to hold the USB port in place while using another adjustable wrench to tighten the locking nut. 8. Reconnect the USB plug on to the receiver on the back of the control board. 5. Perform the installation procedure from 11.2 Control Board Replacement, page 109. Repair and Replacement Procedures 11.5 Nylatron Filler-Strip Replacement Nylatron filler strips are used to cover the open slots the lid's lifting arms use to travel up and down through during normal operation. The strips prevent grease laded vapors and breading from entering the counterbalance weight carriage assembly area in the rear of the unit. The strips do not bear any of the lid's counterbalance weight. One end of the strip is connected to the internal end of the lid's arm, and the other to the counterbalance weight carriage assembly in the back of the unit. The strip moves through a channel in the front shroud as the arm and counterbalance weight carriage assembly moves up and down with the lid. The counterbalance weight carriage assembly is connected to the lid's arms with cables that bear and counterbalance the lid's weight. Without proper cleaning the channels fill with debris and add friction to the movement of the Nylatron filler strips. Eventually the strips fail and must be replaced. Objects can fall and splash hot oil or hot water while performing this procedure. Cover the vat with a sheet pan or drain the vat and allow to cool otherwise serious burns may result. Lid may be hot. Allow lid to cool before performing this procedure, or burns may result. The lid and counterbalance weight carriage assembly moves with force and can cause injury. 112

127 Inspect the Nylatron Filler Strip Kit Part Number: SLIDE-SHROUD VERTICAL Before disassembling the fryer unit, open and inspect the Nylatron filler strip replacement kit. The kit must contains the following components: x2 Nylatron filler strips x2 Counterweight securing carriage bolts x2 Spade connectors Instruction Sheet If parts are missing, contact Henny Penny Service. Contact information is on rear cover Remove the Counterweights and Secure Carriage Assembly The counterweight assembly is attached to one end of the Nylatron filler strips and must be detached during the replacement procedure. Remove the counterbalance weights and secure the counterweight carriage assembly to the rear of the unit to prevent injury or damage by doing the following: Burn Risk. The carrier may be hot. Allow carrier to cool to prevent personal injury. NOTICE: Tighten the 2 counterweight securing bolts to the rear of the unit but do not overtighten or risk stripping out the bolt holes. 1) Raise the lid assembly to its full height and remove the carrier assembly to reduce weight. 2) Close the lid, engaging the front lid hold down. 3) Engage the lid handle by pulling forward on the handle until the lid handle rollers are firmly inside the locking slots. 4) Push down on the handle ensuring both sides are engaged in the locking slots. 5) Using a #2 cross tip (Phillips) screwdriver, remove 4 round head screws from the top access panel and then remove the panel. Do not remove the deadweight valve or the safety relief valve. 6) Using a 3/8 in. nut driver, remove 6 locking flange nuts from the rear access panel and then remove the panel. The weight carriage assembly is visible. 7) Using a large flat head screwdriver or pry bar, separate and remove the individual weights from the counterbalance weight carriage assembly to lighten the assembly. 8) Insert 1 bolt through the upper left corner of the counterbalance weight carriage assembly and tighten using the 1/4 in. hex key wrench. 9) Insert the remaining bolt through the upper right corner of the counterbalance weight carriage assembly and tighten using the 1/4 in. hex key wrench. Repair and Replacement Procedures 113

128 INFO: The counterbalance weight carriage assembly can be moved to align the 2 counterweight securing bolts with the holes in rear of the unit as required Remove the Tilt Stop The tilt stop, also referred to as the lid kickstand, must be removed so the front shroud can be removed. Remove the lid tilt stop by doing the following: 1) Remove the lid tilt stop inner retaining C-Clip. 2) Remove the lid tilt stop assembly by pulling the rod out of the outer side of the lid's left lifting arm. 3) Lay the lid tilt stop assembly aside to a safe and protected space Remove the Lid Assembly Two person procedure. The lid assembly weighs 125lbs. Obtain assistance from another person to remove the lid assembly or serious personal injury may occur. Repair and Replacement Procedures The lid must be removed so the front shroud can be fully removed. Remove the lid by doing the following: 1) Disengage the lid handle by lifting up on the handle, and then pushing back. 2) Obtain a 2 x 4 x 12 in. (40 x 90 mm) block of wood. 3) Disengage the front lid hold down and prop up the lid with the block of wood. Tension on the lid retaining rod is relieved. 4) Remove a C-clip and washer from one side (left or right) of the retaining rod. 5) Remove both inner left and right C-clips from the inner left and right lid grooves. 6) Slide the retaining rod out from the lid's arms and the lid lifting arms. Two washers fall off the retaining rod. 7) Retrieve the two washers and save for reassembly. 8) Obtain assistance from another person to remove the lid assembly. 9) Lift the front of the lid to a 45 degree angle, and then pull forward to remove. 10)Lay the lid aside in a safe and protected space. 11)Cover the vat with a sheet pan Remove the Front Shroud When the counterweight assembly bolts are removed, the counterweight assembly drops pulling the lid's lifting arms up with force. Hold down the lid's lifting arms before removing the bolts or serious personal injury may occur. Remove the front shroud to access the Nylatron filler strip channels on the inside by doing the following: 114

129 1) Using a 1/2 in. open end wrench, remove 2 bolts with lock washers and flat washers connecting the bolt end of the Nylatron filler strips to the counterbalance weight carriage assembly. 2) Obtain assistance from another person. 3) Apply downward pressure on the lid's lifting arms. 4) Remove the 2 counterweight securing bolts, attaching the counterbalance weight carriage assembly to the unit's frame. 5) Slowly allow the lid's lifting arms to slide up to the upper resting position. 6) Using a #2 cross tip (Phillips) screwdriver, remove 4 round head screws from the sides of the front shroud. 7) Push the strain relief wire in to and through the lid's left lifting arm. This is necessary to provide clearance for the front shroud removal. 8) Lean the front shroud toward the front of the fryer and pull forward until it is free of the lid's lifting arms, and then lift up at an angle to remove. INFO: The lid's lifting arm end of the Nylatron filler strip has a D-shaped opening. The rounded portion of the D points inward and the flat side outward Remove the Nylatron Filler Strip Channel Over time the Nylatron filler strip channels fill with debris and add friction to the movement of the Nylatron filler strips. Remove the channels from the back of the front shroud by doing the following: 1) Using a 5/16 in. nut driver, remove 10 nuts and 2 Nylatron filler strip channels from the rear of the front shroud. 2) Remove the Nylatron filler strips from the channel and discard. 3) Clean the channels and the shroud using degreaser, soapy water, a putty knife, and brush as necessary Install the New Nylatron Filler Strip INFO: This remaining sections explain the installation portion of the Nylatron filler strip replacement procedures and assumes the unit is already disassembled. If you did not disassemble the unit, read through the removal steps and familiarize yourself with the disassembly process to prevent injury or equipment damage. Once both Nylatron filler strip channels and front shroud are clean, install the Nylatron filler strip channels, Nylatron filler strips and front shroud by doing the following: 1) Using a 5/16 in. nut driver and 10 nuts, attach 2 Nylatron filler strip channels to the rear of the front shroud cover. 2) Install one each of the new Nylatron filler strips in to each of the 2 Nylatron filler strip channels with the D shaped hole end of the strip towards the bottom of the unit. Repair and Replacement Procedures 115

130 3) Align the two D shaped holes, in the Nylatron filler strips, over both of the lid's lifting arms and carefully guide the bottom and then the top of the shroud in to place. 4) Using a #2 cross tip (Phillips) screwdriver, install 4 round head screws in to the sides of the front shroud. 5) Using a 1/2 in. open end wrench and 2 bolts with lock and flat washers, attach the bolt hole end of the Nylatron filler strips to the counterbalance weight carriage assembly Install the Lid Two person procedure. The lid assembly weighs 125lbs. Obtain assistance from another person to install the lid assembly or serious personal injury may occur. Movement of the counterbalance weight carriage assembly can cause personal injury and equipment damage. Ensure the counterbalance weight carriage assembly is securely affixed to the unit's frame to prevent movement during installation of the counterweights. Repair and Replacement Procedures Install the lid and test the Nylatron filler strips by doing the following: 1) Obtain assistance from another person. 2) Apply downward pressure on the lid's lifting arms. 3) Install the 2 counterweight securing bolts, attaching the counterbalance weight carriage assembly to the unit's frame. 4) Install the counterweights into the counterbalance weight carriage assembly. 5) Obtain a 2 x 4 x 12 in. (40 x 90 mm) block of wood. 6) Place the wood block on the front of the fryer in front of the vat. 7) Remove the sheet pan covering the vat. 8) Place the lid on the vat with the front lip resting on the block of wood and the lid's arms on the outside of the lid's lifting arms. 9) Align the holes in the lid's arms with the holes in the lid's lifting arms. 10)Install 1 C-clip and washer on one end of the retaining rod. The C-clip is on the outside. 11)Slide the opposite end of the retaining rod through the lid's left arm and lifting arm mounting holes. 12)Stop, install two washer on the end of the retaining rod, and then push the retaining rod through the lid's right arm and lifting arm mounting holes. 13)Install a washer and C-clip on the end of the retaining rod. The C-clip is on the outside. 116

131 14)Push the washers against the inside of the lid's lifting arms, and then install both inner left and right C-clips in to the retainer rod's inner left and right retaining grooves Test the Nylatron Strips Move the lid up and down several times to ensure the Nylatron filler strip moves freely in the channel and in synchronization with the counterbalance weight carriage assembly. If the Nylatron filler strip moves freely, continue at Install the Tilt Stop, page 117. If the Nylatron filler strip does not move freely, correct the issue before continuing to Install the Tilt Stop, page Install the Tilt Stop The tilt stop holds the lid open at 45 degrees to make cleaning easier. If the tilt stop (kickstand) is not installed properly the lid can fall with force causing serious personal injury. Install the lid tilt stop by doing the following: 1) Ensure the tilt stop is clean prior to installation. 2) Insert the lid tilt stop assembly's retaining rod through the outside of the lid's left lifting arm, tilt stop hole. 3) Install the inner retaining C-Clip. 4) Test the tilt stop by doing the following: Pull on the tilt stop to ensure the C-clip is fully seated. Raise the lid to 45 degrees and setting the tilt stop in to place, then lower. Repeat several times to ensure the tilt stop does not bind or fail Install the Top and Rear Access Panels Place the rear access panel mounting holes over the mounting studs. The holes do not align exactly, manually manipulate the sheet metal to fit. 1) Using a 3/8 in. nut driver, install 6 locking flange nuts on to the mounting studs and torque snug. 2) Place the top access panel over the side panels, ensuring the safety relief valve assembly is not pinched or hindered. 3) Using a #2 cross tip (Phillips) screwdriver, install 4 round head screws in to the top access panel. 4) Ensure the safety relief valve is not pinched or hindered. Repair and Replacement Procedures 117

132 11.6 High Limit Thermocouples Replacement Disconnect the power or electrical shock will occur. Lowering the control board exposes the technician to 240 VAC electricity inside the fryer. 1. Lift the carrier, tilt back and lock in to place. 2. Use a Phillips head screwdriver to loosen the heating element spreaders. 3. Use a Phillips head bit to remove the screws from the left-hand (from the front of the unit) side panel. 4. Remove the side panel and set aside. 5. Use a 1/2 inch wrench to loosen the compression fitting. 6. Pull the thermocouple from the fitting. Repair and Replacement Procedures 118

133 7. Lower the control board by performing the removal procedure from 11.2 Control Board Replacement, page Trace wires to the high limit modules on the sidewall of the control board area. 9. Remove the wires from high limit module. 10. Use a 1/2 inch wrench to remove fitting from the vat wall. 11. Obtain the new thermocouple and fitting. 12. Apply thread sealant to the fitting and thread into the vat wall. Tighten with a 1/2 inch wrench. 13. Insert the new thermocouple into the compression fitting. INFO: Be sure the new thermocouple slides into the heating element spreader. 14. Extend probe out from vat wall 4.5 inches and clamp to allow.125 inch of the probe to be exposed. 15. Use a 1/2 inch wrench to tighten the compression fitting onto the thermocouple. 16. Position heating element spreader next to clamp. 17. Use a Phillips head screwdriver to tighten the heating element spreader. 18. Connect the new thermocouple wires to the high limit module. 19. Install the side panel, and then the control board by performing the installation procedure from 11.2 Control Board Replacement, page High Limit Module Replacement INFO: Disconnect the power or electrical shock will occur. Lowering the control board exposes the technician to 240 VAC electricity inside the fryer. The upper module controls the lower thermocouple. The lower module controls the upper thermocouple. Repair and Replacement Procedures 119

134 1. Lower the control board by performing the removal procedure from 11.2 Control Board Replacement, page Locate the faulty high limit module on the left-hand (from the front) side wall. 3. Mark all the wire locations, and then disconnect all the wires. 5. Use a 3/8 inch socket or nut-driver to remove the nuts. 6. Remove the two metal lock strips, and then slide the old high limit module off of the mounting studs. 7. Slide the new high limit module on to the mounting studs, and then place the two metal lock strips onto the studs. Repair and Replacement Procedures 11.8 Primary Contactor Replacement NOTICE: 8. Secure in place with a 3/8 inch socket or nut-driver, and then reconnect the wires. 10. Install the control board by performing the installation procedure from 11.2 Control Board Replacement, page 109. Disconnect the power or electrical shock will occur. Lowering the control board exposes the technician to 240 VAC electricity inside the fryer. Do not connect L1 & L2 to a circuit operating at more than 150 volts to ground (gnd) or component damage may result. 120

135 1. Lower the control board by performing the removal procedure from 11.2 Control Board Replacement, page Mark the location of the wires. 3. Use a Phillips head screwdriver to remove the: a) L1, L2, and L3 wires from the contactor. b) T1, T2, and T3 wires from the side of the contactor. c) RS1 and RS2 yellow wires. 4. Use a 3/8 in. nut-driver to remove the nuts that secure the contactor to the shroud. 5. Lift up on the contactor and remove it from the studs. 6. Place the new contactor on to the studs, and then use a 3/8 in. nut-driver to secure in place. 7. Use a Phillips head screwdriver to install the: a) RS1 and RS2 yellow wires. b) T1, T2, and T3 wires to the side of the contactor. c) L1, L2, and L3 wires to the contactor. 8. Install the control board by performing the installation procedure from 11.2 Control Board Replacement, page Heat Contactor Replacement Disconnect the power or electrical shock may occur. Lowering the control board exposes the technician to 240 VAC electricity inside the fryer. Repair and Replacement Procedures 121

136 1. Lower the control board by performing the removal procedure from 11.2 Control Board Replacement, page Mark the location of the wires. 3. Use a Phillips head screwdriver to remove the: a) A1 and A2 blue wires from the contactor. b) 1L1, 3L2, and 5L3 wires from the side of the contactor. c) 2T1, 4T2, and 6T3 wires from the side of the contactor. 4. Use a 3/8 in. nut-driver to remove the nuts that secure the contactor to the shroud. 5. Lift up on the contactor and remove it from the studs. Repair and Replacement Procedures 6. Place the new contactor on to the studs, and then use a 3/8 in. nut-driver to secure in place. 7. Use a Phillips head screwdriver to install the: a) 2T1, 4T2, and 6T3 wires from the side of the contactor. b) 1L1, 3L2, and 5L3 wires from the side of the contactor. c) A1 and A2 blue wires from the contactor. 8. Install the control board by performing the installation procedure from 11.2 Control Board Replacement, page AIF Multi-Tab Transformer Replacement Disconnect the power or electrical shock will occur. Lowering the control board exposes the technician to 240 VAC electricity inside the fryer. 122

137 1. Lower the control board by performing the removal procedure from 11.2 Control Board Replacement, page Mark the location of the wires, and then disconnect. 3. Use a 3/8 in. nut-driver to remove the nuts that secure the transformer to the shroud. 4. Lift up on the transformer and remove it from the studs. 5. Place the new transformer on to the studs, and then use a 3/8 in. nut-driver to secure in place. 6. Reconnect the wires. 7. Install the control board by performing the installation procedure from 11.2 Control Board Replacement, page Control Transformer Replacement Disconnect the power or electrical shock will occur. Lowering the control board exposes the technician to 240 VAC electricity inside the fryer. 1. Lower the control board by performing the removal procedure from 11.2 Control Board Replacement, page Locate the 5-pin connector leading from the transformer, and then disconnect. Repair and Replacement Procedures 123

138 3. Use a 3/8 in. socket and extension to remove the nuts that secure the transformer to the shroud. 4. Lift up on the transformer and remove it from the studs. 5. Place the new transformer on to the studs, and then use a 3/8 in. socket and extension to secure in place. 6. Locate the 5-pin connector leads, and then connect. 7. Install the control board by performing the installation procedure from 11.2 Control Board Replacement, page Pump Motor Replacement Filter motors can be replaced independent of the filter pump or together as an assembly. The following instruction includes the separation of the filter pump from the filter motor. Repair and Replacement Procedures 1. Remove the drain pan, fresh oil pan (ATO), and condensation pan. INFO: The condensation pan is not used on an open fryer, only a pressure fryer. 2. Use an adjustable wrench to remove the flex line and pipe connections from both ends of the pump motor. INFO: A hard tube may be present on pump outlet if this is a newer build. 124

139 3. Use a Phillips head screwdriver to remove the two screws that secure the plate onto the pump motor. 4. Mark the locations of the black wires. 5. Remove the black wires from the pump motor. 6. Use a flat blade screwdriver to remove the conduit retainer ring from the pump motor. 7. Remove the conduit retainer and conduit from the pump motor. 8. Use a 1/2 inch wrench to remove the two nuts on the mounting plate. 9. Lift up on the pump motor then pull it off the mounting plate. 10. If replacing the motor only, remove the two screws connecting the filter pump to the face of the filter motor. 11. Separate the pump and motor assemblies. Repair and Replacement Procedures 125

140 12. Install the two screws connecting the filter pump to the face of the filter motor. 13. Place the new pump motor onto the mounting plate so the hanger bolts rest on the top lip and slide down so the studs are in line with the holes in the pump motor base. 14. Use a 1/2 inch wrench to secure the pump motor to the mounting plate. 15. Use an adjustable wrench to reconnect the lines to the correct port of the pump motor. Repair and Replacement Procedures Pump Motor Seal Replacement The filter pump and filter motor must be seperated for this procedure, see Pump Motor Replacement, page 124. The oil seals prevent oil from migrating into the motor assembly, which can damage the motor. With the new filter motor on a flat sturdy work surface, using seal kit 17476, install the pump seal components on to the new filter pump motor as shown in Figure 11-1 Pump Seal Kit Placement, page 126. Figure 11-1 Pump Seal Kit Placement 126

141 11.14 Pump Motor Roller Replacement The filter pump and filter motor must be seperated for this procedure, see Pump Motor Replacement, page 124. The rollers inside the filter pump that creates the oil pressure, wear and require replacement. Using kit 17446, replace the rollers by doing the following: 1) Remove the four screws attaching the cover to the filter pump, and then remove the cover. 2) Replace the five old rollers with the new rollers. 3) Replace the cover s old o-ring with the new o-ring. 4) Install the cover using four screws on to the filter pump. Figure 11-2 Pump Rollers Repair and Replacement Procedures 127

142 11.15 Flex Tube Replacement Flex tubes carry hot oil under pressure When installing new flex tubes, follow the listed guidelines to prevent failures of the new flex tube. When bending the flex tube do not: - Bend smaller than a golf ball in radius. - Bend more than 3 times in the same area of tube. - Bend the flex tube within 4 finger widths of the end fittings. Discard any tube bent more than 3 times in the same area of tube. When torquing, hold the brass fitting that the flex tube is being torqued onto, to avoid twisting of the flex tube. 1. Notice the routing of the old flex tube before removal. Repair and Replacement Procedures Lid Cable Replacement 2. Use two adjustable wrenches to loosen the brass fitting and remove the flex tube. One wrench holds the flex tube fitting and the other holds the attaching fitting. 3. Use the old flex tube as a template to rough bend the new tube. 4. Install the new flex tube by torquing finger tight, and then turning (torque) an additional 1/4 turn. The weight carriage on the rear of the fryer counter-balances the lid system for ease of operation. Two cables attached to it; the safety cable on the left-side and the lifting 128

143 cable in the middle. The lifting cable tension should be tight and the safety cable tension should be loose enough that when squeezing the cable together, the two sides can touch. Both cables should be replaced in pairs. The white label denotes the cable replacement date and should be affixed to the back of the fryer's frame. 1. Using a 3/8 nut driver, remove the nuts securing rear shroud of the fryer and remove the shroud. 2. Using a Phillips screwdriver, remove screws securing the top cap and remove. 3. Lower the lid until it latches, and then insert two 5/16 carriage bolts, one through each side of the weight carriage and in to the frame to secure the carriage. Ensure the carriage is level. INFO: Carriage bolt holes are provided in the frame for securing the carriage. 4. Unscrew and remove both cables from the weight carriage assembly, and then the chassis. Remove weights as needed. 5. Screw a 5/16 lock-nut on each end of the new cables. 6. Apply blue Loctite thread sealant to the cable threads. 7. Using an adjustable wrench, screw one end of each new cable in to the weight carriage assembly until tight. 8. Using a 1/2 wrench, tighten the locknut against the weight carriage assembly, securing both cables in to place. 9. Thread the cables over the pulleys and down behind the weight assembly. 10. Apply blue Loctite thread sealant to the cable threads. Repair and Replacement Procedures 129

144 11. Insert both cables in to the holes in the chassis, screw a 5/16 nut on to the end of each of the cables, and then tighten. INFO: The lifting cable tension should be tight and the safety cable tension should be loose enough that when squeezing the cable together, the two sides can touch. 12. Tighten the lock-nut against the top of the bracket, securing the cable. 13. Remove the two carriage bolts securing the weight carriage against the fryer s frame. Retain the bolts for future use. 14. Raise the lid up and down to ensure free movement of the weight carriage and that it is level. Correct as needed. 15. Replace the top cap and rear shroud. Repair and Replacement Procedures Label Replacement 16. After replacing both cables, locate the white label. Using a marker or pen, write the cable replacement month and year on the white label as shown. 17. Place the label on the back of the fryer in the area indicated. 18. Place the clear label protector overtop of the white label to prevent ink from wiping away during future cleaning. If a label becomes unreadable it should be replaced. These procedures explain how to remove a label and prepare the surface for the new label. In certain situations it may be quicker and more cost effective to replace the component on the fryer, which ships with a new label attached. As an example, a PXE model fryer has multiple labels 130

145 affixed to the top lid cover and it would be quicker to replace the lid cover than trying to clean off all the label glue and readhering new labels. NOTICE: Do not use a scotch brite pad or other similar abrasive material anywhere on the fryer. 1) Peel off as much of the old, failing label as possible by hand. 2) Use a 3M Adhesive Eraser Wheel in a hand drill to remove the remainder of label, quickly and easily. 3) Wipe away the label debris with a towel. 4) If necessary, remove any remaining adhesive remnant by lightly spraying the surface with 3M citrus based adhesive remover. Let stand for a minimum of five minutes. 5) Gently scrape, scrub and wipe away remaining adhesive remnants. 6) Using isopropyl alcohol wipes, thoroughly clean the surface to remove any oil or other film from the surface. 7) Remove the adhesive liner from new label. 8) Apply the new label, laying the label flat on to the surface. Ideally working from the center of the label outward using the 3M PA-1 blue applicator, which is included. 9) To eliminate any large bubbles, use a pin to create an airhole, and then press down the bubble using the 3M PA-1 blue applicator. Repair and Replacement Procedures 131

146 Repair and Replacement Procedures 132

147 Chapter 12 Zigbee Radio 12.1 Overview Online Projection System (OPS) and Quality and Production Management (QPM) What is OPS/QPM Both the Online Projection System (OPS) and the Quality and Production Management (QPM) systems are KFC initiatives, similar to smart kitchen products, that assists store operators in maintaining an appropriate inventory of cooked food, ready to serve, so that customers do not have to wait for their orders. The computer system performs real-time monitoring of sales, product inventory, product "in process" (being cooked), etc., and consults a history of past sales data in order to project expected sales. Based on projected sales and current inventory, the system prompts the restaurant staff on how much product to cook and when Data Tracking In order to track how much product is being cooked and placed into inventory, the OPS/QPM system communicates directly with the kitchen equipment via an inhouse ZigBee wireless network. It can directly query each fryer, for example, to discover its current operating status: off, on, melt mode, cook mode, currently cooking, etc. Also, the fryer reports the start and end of each cook cycle, as well as which product is being cooked. For some products, like strips, the control asks the user to specify precisely how many pieces are being cooked, and then passes that information on to the OPS/QPM computer. For other products, like various loads of bone-in chicken, the OPS/QPM system is pre-programmed to know how many pieces to expect for the various standard loads Communication Architecture The Digi ZigBee radio is hard-wired to communicate with the fryer s control board but uses wireless to interact with the operator s network. To facilitate two way communication between the Digi radio and fryer, the Digi radio must be properly installed, powered on, and the fryers communication software enabled. In addition, to facilitate communication between the fryer and the virtual (network) environment (Smart Kitchen), the network must see the Digi radio and allow it to join the network to enable seamless two way communication Digi ZigBee Radio Digi is the company that manufactures the radio, and whose name and logo is prominently displayed on the radio, while ZigBee is a wireless technology developed as an open global standard to address the unique needs of low-cost, low-power wireless M2M networks. Zigbee Radio 133

148 Digi Radio The Velocity control board communicates directly with the Digi radio module. The radio modules are manufactured by Digi with firmware customized for Henny Penny, to support operator requirements. The radio module speaks the standard ZigBee protocol on the wireless side, and speaks RS-485 Modbus protocol on the hard-wired side to communicate with the fryer s control board. The radio module basically asks the control for a status update about every 5 seconds, and we send a reply message back to the radio module with the requested information. The radio module then takes care of converting this information to the ZigBee wireless format and broadcasts it on to the ZigBee wireless network ZigBee Protocol ZigBee is the name of a type of wireless communications technology and protocol, just as WiFi and BlueTooth are names for other types of wireless network technologies. The advantage of a ZigBee network particularly in a commercial kitchen where large panels of stainless steel may obstruct other technologies is that ZigBee can form a wireless mesh network, where the various radios that have joined the network are able to forward messages from one device to another. If a piece of equipment is out of range or is blocked from communicating directly with some other piece of equipment at the other end of the building, the radio modules in between can receive and forward messages as needed. That is, if equipment A cannot talk directly to equipment C, but A can talk to B and B can talk to C, then A will send the message to B, and B will pass it on to C. The ZigBee protocol operates in the 2.4 GHz range and is therefore approved for operation worldwide. The data rate in the 2.4 GHz band is about 250 kilobits a second, which is acceptable performance for in-store monitoring of equipment status Mesh Network Zigbee Radio A mesh network is a network topology in which each node relays data for the network. All mesh nodes cooperate in the distribution of data in the network. Mesh networks can relay messages using either a flooding technique or a routing technique. The flooding technique releases the data packets on to the network without specific routing instructions. The routing technique is more sophisticated and requires a table of addresses, which is used to route the data packets from point to point Practical Application In a Smart Kitchen application a ZigBee (wireless) signal can travel through ZigBee (wireless) enabled appliances regardless of which appliance the signal originates from. Each ZigBee (wireless) enabled appliance becomes a node on the network. Eventually the signal reaches a local or virtual (over the Internet) server which contains the Operator s Smart Kitchen software. The upside is the signal from the 134

149 Henny Penny fryer has many additional opportunities to reach the server successfully. The downside is if our signal is blocked by a structure (i.e. wall, distance, etc.) and is using another appliance (node) to reach the server, then we have an additional point of failure. As an example, if the signal is being routed through a refrigerator (node) and not directly connecting to the server, then the refrigerator becomes a point of failure Installation There are two major steps to installing the Digi ZigBee radio; hardware installation and setting configuration. A qualified technician must perform the installation. To avoid electrical shock or property damage, disconnect power before starting installation Install the Hardware 1) On a table or countertop, position the radio adapter so that the terminal block screws are face-up. Attach wire ZB3 to the left-outside terminal (1), and attach wire ZB4 to the right of the left-outside terminal (2). See Figure 12-1 Connecting Wires to Terminal Block, page 135. Figure 12-1 Connecting Wires to Terminal Block INFO: Wire numbers are printed on the exterior insulation of the wire. 2) Using a Phillips head screwdriver, remove the two screws securing the control board and lower it down. Zigbee Radio 135

150 3) Slide the radio on to the studs, located on the side of the control, with the green (9-pin) connector directed towards the fryer. See Figure 12-2 Sliding Radio Module on to Studs, page 136. Figure 12-2 Sliding Radio Module on to Studs 4) To attach the barrel connection to the radio, align the barrel connector with the notches located on the top of the radio. Press in on the barrel and rotate 90 degrees clockwise to lock the connector into place. See Figure 12-3 Attaching Connector to Radio, page 137. Zigbee Radio 136

151 Figure 12-3 Attaching Connector to Radio 5) Using the nuts provided in the kit, secure the radio to the controls with a 1/4 inch socket or nut-driver. See Figure 12-4 Securing Radio to Control, page 137. Figure 12-4 Securing Radio to Control 6) Run the wires underneath the side of the adapter, then connect the 9-pin connector to the control board. See Figure 12-5 Connecting 9-Pin Connector, page 138. Zigbee Radio 137

152 Figure 12-5 Connecting 9-Pin Connector INFO: It is recommended to gather power harness wires and tie with wire tie. See Figure 12-6 Gather Wires in Wire Tie, page 138. Zigbee Radio Figure 12-6 Gather Wires in Wire Tie 7) Place control board back to factory location and secure with the Phillips head screws. 138

153 8) Place the OP decal on the lower right-hand corner of the control board. See Figure 12-7 OP Decal Location, page 139. Figure 12-7 OP Decal Location Configure the OPS/QPM Settings Overview A configuration setting in the fryer control determines whether or not the OPS/QPM features are enabled. This programming operation can be performed whether the fryer is on or off, as long as the control is powered. Special Program Mode allows simple enabling or disabling of the OPS/QPM system on this fryer, but does not provide any further technical or diagnostic support. Diagnostic displays are easily accessible in Info Mode Enable OPS/QPM 1) Press and hold the menu button (1) until *MAIN* displays. See Figure 12-8 Menu & Info Button Locations, page 140. Zigbee Radio 139

154 Figure 12-8 Menu & Info Button Locations 2) Press and release the menu button (1) again, to cycle to the second set of menu options. Figure 12-9 Second Set of Main Menu Options Zigbee Radio 3) Select 4.PROG. See Figure 12-9 Second Set of Main Menu Options, page 140. Programming menus display. 140

155 Figure Programming Menus 4) Select 3.SPCL PROG. See Figure Programming Menus, page ) Using the number buttons, enter code 1, 2, 3. 6) Use the top right arrow to navigate to SP-4 ENABLED. See Figure SP-4 OPS/QPM Enabled, page 141. Figure SP-4 OPS/QPM Enabled 7) Use the plus or minus buttons to change the middle screen to read YES. See Figure SP-4 OPS/QPM Enabled Yes Display, page 142. Zigbee Radio 141

156 Figure SP-4 OPS/QPM Enabled Yes Display 8) Press and hold the menu button to exit special program mode Verify Communication Verify the Digi radio can communicate with the fryer s control board and the network. OPS/QPM must accept the Digi radio to complete the connection and seamless data connection. 1) Press the menu (1) and info (2) button at the same time until ==INFO MODE== is displayed. Release both buttons. See Figure 12-8 Menu & Info Button Locations, page ) Press the left-arrow button to cycle to the last menu option. The Join Status screen displays. See Figure Join Status Display, page 142. Zigbee Radio Figure Join Status Display 3) The middle display reads ZigBee with either a check mark, a dash or a flashing X. See descriptions below: : Control has received a good message within the past 15 seconds. 142

157 - : Last good message was more than 15 seconds but less than 60 seconds ago. X: Control has not received a good message in more than 60 seconds. INFO: These messages only indicate if the Digi radio and control board are communicating. It does not mean the Digi radio is communicating with the network. 4) The bottom display reads JOIN = followed by a value. If the value reads 00, this means the radio is joined to the network. Any other value means the radio is not joined to the network. 5) Use the down arrow to navigate to the Channel Status screen. See Figure Channel Status Display, page 143. Figure Channel Status Display 6) The bottom display reads CHAN= and gives a value. If the radio is joined to a network, that particular channel s number displays. If the radio is not connected to a network, that value reads 00. 7) Use the down arrow to navigate to the PAN ID display screen. See Figure Pan ID Display, page 144. Zigbee Radio 143

158 Figure Pan ID Display 8) The bottom display reads PAN ID followed by a value. If the radio is joined to a network, the ID number displays. If the radio is not connected to a network, FFFF displays. 9) Use the down arrow to navigate to the Radio Short ID display screen. See Figure Radio Short ID Display, page 144. Figure Radio Short ID Display Zigbee Radio 10)The bottom display reads RADIO followed by a value. If the radio is joined to a network, that particular radio module number displays. This varies for each radio and may change if the radio is unjoined and then rejoined to a network. If the radio is not connected to a network, FFFF displays. 11)Use the down arrow to navigate to the Reset/Unjoin Command display screen. See Figure Reset/Unjoin Command Display, page

159 Figure Reset/Unjoin Command Display 12)The bottom display reads RESET followed by a value. if the value is 00, no reset is required, or the requested reset has been completed. If the value is 01, a reset is pending. 13)To reset, press and hold the button next to RESET. The display counts down. 14)Once the count-down has expired, release the button and the radio now shows 01 for the reset code. The 01 remains until the radio completes the reset operation, then the code changes back to )Press and hold the menu button to exit out of Info Mode Cook ID Code The OPS/QPM system in the store must be configured so that it understands which products are being cooked by the Velocity fryer. When a cook cycle is started, the data sent by the fryer s control board (software) to the OPS/QPM system sends only a product number for the product being cooked, not the actual product name. The product number assignments are determined by KFC and change periodically. The product number mapping on the fryer is updated when the KFC menu is updated on the fryer s control board Verifying the Cook ID Code Each Cook Menu item has a unique product number that communicates with the instore system. To check each product code do the following: 1) Select a number button from the number pad to access the product menus. See Figure Number Buttons, page 146. Zigbee Radio 145

160 Figure Number Buttons 2) With the products displayed on the screen, press and hold the same number button. See Figure Display, page 146. Figure Display 3) After a few seconds, each product name shows their unique product number. See Figure Unique Product Number Display, page 146. Zigbee Radio Figure Unique Product Number Display 146

161 4) Use the product number to identify what product is being cooked. For example, P3 represents Product ZigBee Identify Response Identify Overview Even though the OPS/QPM computer is able to list any new radios detected within range of the network, there is nothing on the OPS/QPM screen that identifies what piece of equipment that radio is installed in. For example, if two new fryers are brought into the store on the same day, the OPS/QPM computer screen would see two new radios available, but there would be no way to know which radio is installed in which fryer. To clearly identify which radio corresponds to which fryer, every ZigBee device must implement an audio-visual Identify response. When the Identify command is sent from the OPS/QPM computer to a fryer s radio module, the fryer control itself must beep and display a message to make it clear which piece of equipment to which the OPS/QPM computer is communicating Configuring the Identify Response For stores that have multiple units and need to quickly identify each unit s channel ID, a signal can be sent from the OPS/QPM operating computer to the units. Once the channel ID is selected, the unit that is linked to that ID starts to flash ZIGBEE ID, and then beeps. See Figure ZigBee ID Display, page 147. A note can then be inserted in the OPS/QPM system to identify that ID with the correct unit. Figure ZigBee ID Display INFO: If you are having issues linking the control to the Online Projections System, please contact the KFC Help Desk at HELP-KFC ( ) Troubleshooting Overview In order for seamless communication between the fryer s control board and the operator s data tracking system the following steps are required: Zigbee Radio 147

162 The Digi radio must have uninterrupted power from the fryer s control board. The fryer s control board must be able to communicate (pass data) bidirectionally with the Digi Radio over the wired connection. The Digi radio must be able to convert data into the ZigBee network protocol. The Digi radio must be able to transmit wireless data using the ZigBee protocol. The Digi radio must be seen on the operator s network. The Digi radio must be able to Join the operator s OPS/QPM environment, which is KFC specific. Each of these steps can be a failure point Digi ZigBee Radio Basics Network Connectivity Just because a Digi ZigBee radio module can hear transmissions from a ZigBee network, it does not mean the radio module is part of that network. In fact, any particular module may be able to hear transmissions from multiple ZigBee networks just as your laptop may hear transmissions from multiple wireless networks though it can connect to only one at a time, or might not be connected to any. When our controls and radio modules leave Henny Penny, they are sent out in an Unjoined state, which means they are not a member of any particular network group. Joining a radio is the process of having it locate and join a particular ZigBee network Joining a Network The radio must be manually invited by the OPS/QPM computer to join the store s ZigBee network. The OPS/QPM computer screen lists all the nearby radio modules that the network can communicate with and the operator selects a module and invites it to join the network. INFO: There are options available in the ZigBee protocol to support an "auto-join" feature, but KFC is currently manually joining new radios at this time. Zigbee Radio Once joined to the network, the radio automatically reconnects to that same network at each power up. Even if a fryer is unplugged and powered down for days, the radio module remembers the network that it has been assigned to, and automatically reconnects to it again the next time the fryer is plugged in Data Communication The Digi radio can be powered on but not communicating. The radio needs to communicate with both the fryer s software (control board) and the operator s virtual network in order to seamlessly pass data. As an example, the data can flow successfully between the fryer and the Digi radio but never make it on to the operator s virtual network, which inhibits the fryer s data from reaching the operator s Smart Kitchen software. Conversely the data may never make it from the fryer to the 148

163 Digi radio because the radio was improperly installed, damaged, setting changes, fryer moved to a new location, or due to software or hardware failures. Ensure seamless data communication by doing the following: Verify Power The Digi radio operates on 12 VDC. A power cable is provided in the kit. The barrel end of the wire is notched and plugs directly in to the Digi Radio. The other end is connected to a 9-pin connector and connects in to the back of a control board, to receive power. See Figure 12-1 Connecting Wires to Terminal Block, page 135 and also Figure 12-5 Connecting 9-Pin Connector, page 138. Ensure the unit has power by doing the following: 1) Verify the Power light, that is adjacent to the barrel connector on the Digi Radio, is illuminated. If yes, continue to Communication Cables, page 149. If no, continue to step 2. 2) Verify the 9-pin connector is connected correctly, and not reversed. See Figure 12-1 Connecting Wires to Terminal Block, page 135 and also Figure 12-5 Connecting 9-Pin Connector, page 138. Also, refer to. If correctly wired, continue to step 3. If incorrectly wired, repair and verify if the Digi Radio has power. 3) Use a volt meter to verify the control board s 9-pin connector is providing 12 VDC of power. The barrel connector sleeve (ring) is negative, and the tip (interior) is positive. If yes, order a new Digi Radio and/or power cable. If no, diagnose and repair the control board s power source (transformer) Communication Cables Two communication wires connect between the Digi radio s terminal block and a 9-pin connector, the same 9-pin connector that the power wires connect to for a power source. These two wires provide the signals for half duplex communication between the Digi radio and the fryer s control board. Ensure seamless data communication between the Digi radio and control board by doing the following: Check the Wires Verify the 9-pin connector is connected correctly, and not reversed. See Figure 12-1 Connecting Wires to Terminal Block, page 135 and also Figure 12-5 Connecting 9-Pin Connector, page 138. Also, refer to. If correctly wired, continue to Check Data Communication, page 149. If incorrectly wired, repair and verify seamless data communication Check Data Communication If the Digi radio hardware is installed and operating correctly, verify the fryer s control board (software) is communicating with the Digi radio. Refer to Configure the OPS/QPM Settings, page 139. Zigbee Radio 149

164 - If SP-4 OPS/QPM Enabled is set to YES the control board monitors the RS-485 data link for messages from a ZigBee radio module and responds appropriately when requests are received. Continue at Join or Re-Join the Network, page If SP-4 OPS/QPM Enabled is set to NOthe control board does not attempt to communicate with the radio module (via RS-485). All ZigBee related information (displays) indicates OPS/QPM is -OFF-. Set OPS/QPM Enabled to YES and then continue at Join or Re-Join the Network, page 150. INFO: Setting OPS/QPM System Enabled? to NO does not actually disable the radio module or prevent it from communicating with the ZigBee network. It simply configures the fryer s control board software to ignore the radio module and ignore all things related to OPS/QPM (i.e. batch size requests, etc.). The radio module can talk to the wireless network; however, the control board (software) will not respond to the radio Join or Re-Join the Network Complete the steps in section Verify Communication, page 142 and ensure the fryer s Digi radio is Joined to the OPS/QPM network. Continue diagnostic steps as necessary by referring to ZigBee Radio Info Display, page ZigBee Radio Info Display Use the information obtained from the ZigBee radio information display to further diagnose technical issues Access the Display Access Info Display by doing the following: 1) Press the Menu and Info buttons together at the same time. Release the buttons once == INFO MODE == displays. 2) Press the left-arrow button once. The OPS/QPM RADIO screen displays. Zigbee Radio INFO: Info Mode can not be used to enable or disable the OPS/QPM system. It simply provides access to the ZigBee Radio Info Display if the OPS/QPM system has already been enabled. The same information is available in Data Comm program mode, as item DC JOIN Screen ZigBee: The check mark next to the ZigBee text in the middle display indicates that the module is actively receiving good messages from the radio module over the RS485 wired connection to the control. The check mark indicates that the radio module and fryer s control board are communicating with each other. It does not indicate the radio is talking to the in-store wireless network. If the radio status displays a: 150

165 : Control has received a good message within the past 15 seconds. - : Last good message was more than 15 seconds but less than 60 seconds ago. X: Control has not received a good message in more than 60 seconds. Figure Screen 1 JOIN: The number displays join status reported by the radio module to the control. 00 means the radio is currently joined to a network. 21, 23, or FF are typically shown for a radio module that is currently not joined to any network. Other, transient values may appear when the radio has just powered up or is in the process of joining or unjoining a network CHANNEL Screen Displays the radio channel currently being used by the radio and network. If the radio is not currently joined to any network, 00 is typically displayed. Figure Screen 2 Zigbee Radio 151

166 PAN ID Screen Displays the PAN ID number (Personal Area Network ID) of the ZigBee network the radio is currently joined to. If the radio is not currently joined to any network, FFFF is typically displayed. Figure Screen RADIO SHORT ID Screen Displays the Short ID of the radio module, as it is currently addressed on the network. The number is dynamic and is assigned by the Operator s network coordinator device when the radio module joins the network. The number is not necessarily tied to any static property, MAC address, or serial number of the radio itself. If the radio is unjoined from the network, then rejoined to the same network, it might end up with a different Short ID number. If the radio is not currently joined to any network, FFFE is typically displayed. Zigbee Radio Reset / Unjoin Command Figure Screen 4 This option resets the radio module; Or rather, asks the radio module to reset itself. The radio module unjoins the network. 152

167 Figure Screen 5 The number to the right of the RESET field displays the pending reset command. 00 means no reset is in progress. 01 means the process of resetting the radio module has been initiated, but the radio module has not received the message to reset itself yet. To perform the reset operation, the user must press the button to the left of RESET. While holding the RESET button, the control beeps loudly and displays a countdown: 3,2,1... If the user continues holding the button until the countdown expires, the reset code is changed from 00 to 01, indicating a reset operation is in process. After the radio unjoins the network, 00 displays. If the radio is already unjoined from the network, it might not respond to this command. In this case, the 01 status may display until the next time the control is turned off and back on again, which returns the control s reset code to Modbus Packet Statistics Displays statistics about the data packets received from the radio module (i.e. the wired RS-485/Modbus communications link between the ZigBee radio module and the control). These packets do not have any relationship to the wireless side of things and do not indicate anything about whether the radio is sending or receiving ZigBee wireless data. Zigbee Radio 153

168 Figure Screen 6 While on this display, the control chirps each time a good packet is received. A joined radio normally communicates with the control about every five seconds. The control sends a reply to the radio after each valid packet, and the radio normally sends several packets at each exchange. An unjoined radio module sends fewer packets and less frequently. Each Modbus data packet must follow a certain format and must have a valid checksum byte, which confirms the integrity of the packet. If the checksum value is invalid, or if there is an interruption in the middle of the transmission, etc., the packet is discarded and the bad packet count is incremented Modbus Character RX/TX Statistics Displays counts of the number of bytes received by the control from the radio module (RX), and the number of bytes transmitted by the control to the radio module (TX). These are characters on the wired RS-485 link between the radio module and the control. They do not reflect anything about the wireless side of things. Zigbee Radio Figure Screen 7 154

169 In our particular RS485 implementation, the control hears its own transmissions, so it can confirm that what it sent was transmitted correctly. The RX count reflects only the characters received from other devices (i.e. from the radio module). It does not include the characters the control sent. Zigbee Radio 155

170 Zigbee Radio 156

171 Chapter 13 Replaceable Parts 13.1 Parts Introduction This section lists the replaceable parts of the Henny Penny Velocity Series Open Fryer Genuine Parts Use only genuine Henny Penny parts in your fryer. Using a part of lesser quality or substitute design may result in damage to the unit or personal injury When Ordering Parts Once the parts have been identified from the parts list, write down the item number, part number, description, product number, serial number, and voltage. INFO: Examples provided. Parts Information Data Plate Information Item Number 2 Product Number Part Number Serial Number 0001 Description High Limit Voltage Prices Your distributor has a price parts list and will be glad to inform you of the cost of your parts order Delivery Commonly replaced items are stocked by your distributor and will be sent out when your order is received. Other parts will be ordered, by your distributor, from Henny Penny Corporation. Normally, these will be sent to your distributor within three working days Warranty All replacement parts (except lamps and fuses) are warranted for 90 days against manufacturing defects and workmanship. If damage occurs during shipping, notify the carrier at once so that a claim may be properly filed. Refer to the warranty for other rights and limitations Recommended Spare Parts For Distributors Recommended replacement parts are indicated with A or B in the parts lists: - A: Indicates the parts should be stocked on service vans or trucks. - B: Indicates the parts should be stocked at the distributor/kes location. Replaceable Parts 157

172 Inventory on all other parts not identified, should be based upon usage in the territory. Please use care when ordering recommended parts, because all voltages and variations are marked. Distributors should order parts based upon common voltages and equipment sold in their territory. Figure 13-1 Components Item No. Part No. Description Qty. 1A ROLLER - LINKAGE SHAFT 2 2A COVERED POWER SWITCH CASTER 4 INCH SWIVEL STEM 2 Replaceable Parts ASSY - DRAIN PAN OFX (see Figure 13-2 Drain Pan Assembly, page 159 for breakdown.) CASTER RIGID W/ END BRAKE FRESH OIL TANK 1 7A ASSY - OXE100 CONTROL 1 8* DECAL - PXE B* ASSY - SPEAKER 1 Recommend Parts: A = Truck Stock / B = Dist. Stock * = Not Shown 1 158

173 Item No. Part No. Description Qty. 10* ZIGBEE RADIO 1 11B* LID ROLLER KIT 1 12* WELD ASSY - OXE /8 CARRIER 1 13* KIT ORIFICE CLEANOUT PXE 1 Recommend Parts: A = Truck Stock / B = Dist. Stock * = Not Shown Figure 13-2 Drain Pan Assembly Item No. Part No. Description Qty ASSY - DRAIN PAN PFX WELD ASSY - FILTER DRAIN PAN CASTER - 2 IN SWIVEL MTG PLATE 4 4 NS SERRATED FLANGE LOCKNUT 1/ Recommend Parts: A = Truck Stock / B = Dist. Stock * = Not Shown / AR = As Required Replaceable Parts 159

174 Item No. Part No. Description Qty WELD ASSY - FILTER SECTION WELD ASSY - CARRIER CLIP WELD ASSY - CRUMB CATCHER 1 8A O-RING SUCTION LINE ASSY - DRAIN PAN COVER PFX 1 10B* PHT FILTER ENVELOPES - 100CT AR 11* WELD ASSY - PNP UNIT 1 Recommend Parts: A = Truck Stock / B = Dist. Stock * = Not Shown / AR = As Required Replaceable Parts 160

175 Figure 13-3 Heating Elements Item No. Part No. Description Qty. 1A ASSY - 2 IN RTD PROBE 1 2B ELEMENT - HEATING 8.5 KW (208V) 1 2B ELEMENT - HEATING 8.5 KW (240V) 1 2B ELEMENT - HEATING 8.5 KW (480V) 1 2B ELEMENT - HEATING 8.5 KW (200V) 1 Recommend Parts: A = Truck Stock / B = Dist. Stock * = Not Shown / AR = As Required Replaceable Parts 161

176 Item No. Part No. Description Qty. 2B ELEMENT - HEATING 8.5 KW (230V) 1 2B ELEMENT - HEATING 8.5 KW (220V) SPREADER - ANGLED SPREADER - TAP PLATE CLIP - HIGH LIMIT WELD ASSY - HI LIMIT CLAMP CLIP 2 7* SC SCREW - HIGH LIMIT CLAMP SPREADER - HI LIMIT ANGLED SPREADER - HI LIMIT TAP PLATE 2 10* SC SCREW - #10-32 X 5/8 PH FHD SS O RING - CRUMB SWEEP 2 12* FITTING - CRUMB SWEEP 2 Recommend Parts: A = Truck Stock / B = Dist. Stock * = Not Shown / AR = As Required Replaceable Parts 162

177 Figure 13-4 Thermocouple, Heat Contactor & Control Transformer Item No. Part No. Description Qty. 1B CONTROL - WATLOW HIGH LIMIT (208V) 2 1B CONTROL - WATLOW HIGH LIMIT (CE) 2 2* HL SWITCH - MOMENTARY SPLASH PROOF 1 3B CONTACTOR - SQUARED D-24V 1 4 EF BREAKER - PUSH BUTTON RESET 2 5* EF FUSE HOLDER - 20A 250V 2 6* EF FUSE 15 AMP 2 7B CONTACTOR - 24 VAC COIL 1 8B ASSY - 24V/240V 75VA TRANSFORMER 1 9 TS TRANSFORMER 1 10* ME P&B T92 RELAY 12VDC COIL 30AMP 1 Recommend Parts: A = Truck Stock / B = Dist. Stock * = Not Shown Replaceable Parts 163

178 Figure 13-5 Left Side Vat Item No. Part No. Description INFO: Only OXE (Open Fryer) components are called out INSULATION - POT LEFT SIDE 1 2A ASSY - 2 IN RTD PROBE (High/Low Oil Levels) 2 3A THERMOCOUPLE - HI LIMIT 2 Qty. 3A THERMOCOUPLE - HI LIMIT PROBE (CE) (International only) 2 Replaceable Parts Recommend Parts: A = Truck Stock / B = Dist. Stock 164

179 Figure 13-6 Bottom Of Fryer Item No. Part No. Description Qty. 1B MOTOR - 1/2 HP FILTER PUMP (60 Hz) 1 1B MOTOR - 1/2 HP FILTER PUMP (50 Hz) 1 2B* ASSY - FILTER PUMP - 8 GPM FLEX LINES (See Table 13-1 Flex Lines, page 166 for part numbers and lengths) 4B DRAIN VALVE W/ ACTR 4-PIN CONN 1 4B DRAIN VALVE (only) 1 4B DRAIN VALVE O-RING (only) 1 Recommend Parts: A = Truck Stock / B = Dist. Stock * = Not Shown / AR = As Required Replaceable Parts 165

180 Item No. Part No. Description Qty. 4B* ACTUATOR (only) 1 5B VALVE-CHECK SAE 12 (max 200 psi) AR 6A ASSY - 2 IN RTD PROBE 1 7B ASSY - LH DRAIN PAN SW W/ CONN FORM TUBE KIT (NO SELECTOR VALVE) FORM TUBE KIT (BULK OIL) (WITH SELECTOR VALVE) PUMP MOTOR SEAL KIT FILTER PUMP ROLLER KIT 1 Recommend Parts: A = Truck Stock / B = Dist. Stock * = Not Shown / AR = As Required Part Number Length Table 13-1 Flex Lines inch inch Replaceable Parts 166

181 Figure 13-7 Front Top View Item No. Part No. Description Qty SLIDE - SHROUD VERTICAL BRACKET/WHEEL ASSEMBLY LID COUNTERWEIGHT CABLE COUNTERWEIGHT BAR FULL AR COUNTERWEIGHT BAR HALF AR Recommend Parts: A = Truck Stock / B = Dist. Stock * = Not Shown / AR = As Required Replaceable Parts 167

182 Figure 13-8 Pump and Valve Item No. Part No. Description Qty. 1B SVC PACK PXE/OXE JIB RETRO-230V (before May 1, 2015) 1 1B B PUMP MOTOR-120V (after May 1, 2015) 1 PUMP MOTOR-230V (after May 1, 2015) 1 2B VALVE - CHECK SAE 12 (max 200 psi) AR FLEX LINES (see Table 13-2 Flex Line, page 168 for part numbers and lengths.) Replaceable Parts Recommend Parts: A = Truck Stock / B = Dist. Stock AR = As Required Part Number Length inch inch Table 13-2 Flex Line 168