Service Manual - Whaley Food Service
Contents
1. 6 PLEXIGLAS CANOPY 7 ECONOMATE AND AEROHOT SALAD BARS 7 CASTER REP EAC EVEN EREE a E EEEa 8 8 Heritage Thurmaduke 8 Duke Salad Bar Models 8 RECHARGING REFRIGERATION 5 9 TOOLS 9 CHARGING PROCEDURE issn idconsiexsiancienicaniaxianasupanaiauscemanbusantianhtiasaaxaiannnnetonanivs 9 TROUBLESHOO TING PROCEDURE 10 MAINTENANCE 10 STAINLESS STEEL CARE AND CLEANING wisaccscsteissiccssticxssvecinanvecnaanaabsonedancuaieanse 10 CARE AND CLEANING PAINTED OR POWDER COATED 11 CLEANING THE 11 Mechanically Cooled Buffets and Salad Bars MECHANICALLY ASSISTED COLD PAN SPECIFICATIONS MODEL DESCRIPTION VOLTAGE HEIGHT WIDTH HB5CM Heritage 120VAC amp 220VAC 36 24 1 HB3CM N7 HB5CM N7 Heritage NSF Standard 7 120VAC amp 220VAC 36 24 10 25 316 25 amp OVAC 8 220 6 10 31525N7 31625N7 amp 32725 7 AeroServ NSF Standard 7 120VAC amp 220VAC 36 24 1 322. Remove the Vent Cover to gain access to the Thermostat Mounting Bracket 3 Tag and disconnect Thermostat wiring 4 Remove Thermostat mounting screws 5 Remove Thermostat Probe from Evaporator coil Be very careful not to damage the evaporator coil 6 Install the replacement Thermostat NOTE Do not kink Thermostat Probe 7 Install Thermostat Probe in Evaporator Coil 8 Refer to tags to connect Thermostat wiring 9 Install Vent Cover 10 Connect unit to power source and test operation POWER ON OFF SWITCH Power ON OFF Switch Figure 2 Power ON OFF Switch Location The Power ON OFF Switch is part of the conditioner assembly It is mounted below the thermostat on the left side of the condenser The conditioner assembly is available as 115VAC and 220VAC models Ensure that a properly rated switch is available for the unit being worked on 1 Remove the unit from its power source 2 Remove the screws that hold the switch plate on 3 Remove the screws that hold the switch in place on the electrical box 4 Pull the switch out of the electrical box 5 Tag and disconnect the wires to the switch Refer to the tags to reconnect the wires to the replacement switch 7 Push the switch into the electrical box CAUTION Make sure the wires are dressed A properly as the switch is inserted back into the box 8 Using the screws provided with the new switch reattach the switch to the electrical box Mech
3. 46 60 74 amp 88 Thurmaduke Serving System 120VAC amp 220VAC 36 32 32 46 60 74 amp 88 N hurmaduke Serving em N andard OVAC amp 220VA 6 NG32 46 60 74 Next Generation 5 Deep 120VAC 36 32 NG32 46 60 74CP Next Generation 8 Deep 120VAC 36 32 N 46 60 74 Next Generation 8 Deep N andard OVA 6 NG32 46 60 74CP7 Next Generation 10 Deep NSF Standard 7 120VAC 36 32 34 5 7M Duke Salad Bar 120VAC amp 220VAC 36 24 1 5 7M N Duke Salad andard old Pan OVAC amp 220VA 6 1 Note Table does not include canopy dimensions INSTALLATION LOCATION ELECTRICAL CONNECTION The unit represented in this manual is intended for indoor use only Be sure the chosen location has a floor strong enough to support the total weight of the unit Reinforce the floor if necessary to provide for maximum loading For the most efficient operation be sure to provide good air circulation inside and out LEVELING Be sure that the units are placed on a firm flat surface floor Check for cracks in flooring or tile and avoid these areas if possible If necessary place support pads properly rated for the weight of the unit to bridge uneven or cracked flooring Use the adjustable legs to level unit properly STABILIZING Use the leg adjustments to insure that the unit is solid to the floor surface at all four contact points Insure that the unit does not rock w
4. 853 314 231 1130 Fax 314 231 5074 www dukemfg com P N 219231
5. HER APPLIANCE WARNING DO NOT OPERATE THIS EQUIPMENT WITHOUT PROPERLY PLACING AND SECURING ALL COVER AND ACCESS PANELS CAUTION Observe the following e Provide and maintain adequate minimum clearances from all walls and combustible materials e Provide and maintain adequate clearance for air openings e Keep the equipment area free and clear of combustible material e Operate equipment only the type of electricity indicated on the specification plate e Retain this manual for future reference Me Mechanically Cooled Buffets and Salad Bars TABLE OF CONTENTS MECHANICALLY ASSISTED COLD PAN SPECIFICATIONS 4 INSTALLATION 4 alo ai 4 4 STABILIZING sneri a a A EEE A E E REE 4 ELECTRICAL CONNEC THOM 4 PARTS REMOVAL AND REPLACEMENT PROCEDURES 5 THERMOSTAT E EEE 5 POWER CIN OR 5 EVAPORATOR 6 REFRIGERATION 6 DRAIN REPLACEMEN T
6. Service Manual COOLED BUFFETS AND SALAD BARS Please read this manual completely before attempting to install operate or service this equipment This document is prepared for trained Duke service technicians It is not to be used by anyone not properly qualified to perform these procedures This Service Manual is not all encompassing If you have not been trained on servicing this product be sure to read the manual completely before attempting servicing Be sure all necessary tools test equipment and skills are available Those procedures for which you do not have the proper skills and test equipment must be performed only by a qualified Duke trained service technician This manual is copyright 2011 Duke Manufacturing Company All rights reserved Reproduction without written permission is prohibited Duke is a registered trademark of the Duke Manufacturing Company Duke Manufacturing Company 2305 N Broadway St Louis MO 63102 800 735 3853 314 231 1130 Fax 314 231 5074 www dukemfg com P N 219231B Mechanically Cooled Buffets and Salad Bars IMPORTANT WARNING AND SAFETY INFORMATION WARNING READ THIS MANUAL THOROUGHLY BEFORE OPERATING INSTALLING OR PERFORMING MAINTENANCE ON THE EQUIPMENT WARNING FAILURE TO FOLLOW INSTRUCTIONS IN THIS MANUAL CAN CAUSE PROPERTY DAMAGE INJURY OR DEATH WARNING DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN THE VICINITY OF THIS OR ANY OT
7. able material from the system Duke Manufacturing recommends the following triple evacuation method Failure to follow this procedure may result in poor refrigeration system performance AN WARNING NEVER USE OXYGEN OR ACETYLENE IN PLACE OF DRY NITROGEN OR REFRIGERANT FOR LEAK TESTING A VIOLENT EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR DEATH WHEN USING NITROGEN TO PRESSURE TEST ALWAYS USE A PRESSURE REGULATOR FAILURE TO DO SO WILL RESULT IN EXTREMELY HIGH PRESSURE OF THE COMPRESSOR OR OTHER SYSTEM COMPONENTS AND RESULT IN PROPERTY DAMAGE PERSONAL INJURY AND DEATH 1 Evacuate system to 1500 microns 2 Break the vacuum to 2 psig with dry nitrogen If dry nitrogen is unavailable use same type of refrigerant as used in system Evacuate system to 1500 microns 4 Break the vacuum to 2 psig with dry nitrogen If dry nitrogen is unavailable use same type of refrigerant as used in system 5 Evacuate system to 500 microns The system is now ready to receive refrigerant charge according to information on data plate NOTE Prior to repair ensure that there is enough process hose approximately 12 present to complete the repair using the above procedure If not install a new process hose before repair sequence 1 Install a temporary access valve on the high and low sides of the process hoses as close to factory crimps as possible 2 Use temporary valves to perform repair Duk
8. anically Cooled Buffets and Salad Bars 9 Reattach the switch plate 10 Reconnect the unit to its power source and ensure that the switch is working properly EVAPORATOR The evaporator coils are held in place on the bottom of the cold pan with aluminum tape and imbedded in insulating foam They cannot be replaced REFRIGERATION SYSTEM REPLACEMENT Figure 3 Refrigeration Assembly Location The Refrigeration Assembly is located in the front of the unit Disconnect the unit from its power source Remove the vent cover Using a Refrigeration Charging Unit evacuate refrigerant from the system according to Duke Manufacturing Service Bulletin Number 26 4 Taganddisconnectthe evaporator tubing from Refrigeration Assembly 5 Remove the Refrigeration Assembly mounting hardware 6 Tag and disconnect wiring at the junction box 7 Pull the Refrigeration Assembly through the vent opening 8 Thoroughly clean the Refrigeration Assembly compartment NOTE Before installing the replacement Refrigeration Assembly pressure check the evaporator coils for leaks 9 Place the replacement RefrigerationAssembly onto the slide bars 10 Slide the Refrigeration Assembly in to the original position 11 Install the Refrigeration Assembly mounting hardware 12 Refer t
9. cessive run times Continuous operation with dirty or clogged condenser coils can result in compressor failure Mechanically Cooled Buffets and Salad Bars Neglecting the condenser coil cleaning procedures will void the compressor warranty CAUTION Never use a high pressure water wash to clean the condenser AN High pressure wash can damage electrical components located at or near the condenser coil Condenser Coil Figure 10 Condenser Coil VentCover Removed The condenser coil is located and accessed from the front of the unit see Figure 2 A vent cover protects the condenser from damage see Figure 1 The condenser coil requires regular cleaning and should be done every 60 days However if large amounts of dust and grease accumulate clean the condenser coil every 30 days For light dust use a soft non wire brush For heavier dust use a vacuum cleaner or blow with compressed air For heavy grease use a degreasing agent made specifically for condenser coils on refrigeration units Spray the degreasing agent on the coil and then blow with compressed air Never wash the condenser with high pressure water High pressure water can damage or bend the cooling fins on the condenser reducing its efficiency Water can also damage the electrical components located near the condenser coil 11 Duke Manufacturing Company 2305 N Broadway St Louis MO 63102 800 735 3
10. e Manufacturing will not reimburse the cost of permanently installed valves 3 After completing repair evacuate system using the triple evacuation method described in Duke Manufacturing Service Bulletin Number 26 4 After completing proper evacuation method recharge the system using the proper refrigerant according to information on the data plate 5 Crimp process hose just below the temporary valve and again 2 below the first crimp 6 With the crimp tool in place remove the temporary valve 7 Braze shut the end of process hose 8 Allow brazed end to cool for about 5 minutes 9 Remove the crimp tool 10 Check the brazed end for leaks Mechanically Cooled Buffets and Salad Bars 47 TROUBLESHOOTING PROCEDURE SYMPTON POSSIBLE CAUSE REMEDY Cabinet too warm Unit not plugged in Thermostat set too warm Thermostat switch stuck open in coldest position Evaporator fan not running Condenser fan motor not running Dirty condenser coil or filter Refrigerant leak Cabinet too cold Thermostat set too cold Thermostat switch is stuck in the closed position Water in bottom of unit Drain hose plugged Drain hose loose or disconnectedfrom drain pan Plug unit in Set thermostat to a higher number for a colder temperature Replace thermostat Check and repair or replace motor Check and repair or replace motor Clean coil or filter Find leak repair and recharge Set thermostat t
11. hen pressure is applied to the top corners Locking casters are provided on portable models Stabilize the unit by placing spacers between one of the locking casters and the floor until the unit is firm at all four corners Make sure the casters are locked whenever the unit is in service Most cold pan models are available as 120VAC 60 Hz or as a 220VAC 50 Hz Check the model specifications for the correct power source All electrical connections must be performed by a certified electrician and must comply with local electrical codes for the municipality AN WARNING REFER TO THE AMPERAGE DATA LIST IN THE SPECIFICATIONS OR THE SERIAL TAG DATA AND YOUR LOCAL CODE OR THE NATIONAL ELECTRICAL CODE TO BE SURE UNIT IS CONNECTED TO THE PROPER POWER SOURCE A PROTECTED CIRCUIT OF THE CORRECT VOLTAGE AND AMPERAGE MUST BE RUN FOR CONNECTION OF THE SUPPLY CORD OR PERMANENT CONNECTION TO THE UNIT THE POWER MUST BE TURNED OFF AND DISCONNECTED WHENEVER PERFORMING MAINTENANCE OR REPAIR FUNCTIONS MT Mechanically Cooled Buffets and Salad Bars PARTS REMOVAL AND REPLACEMENT PROCEDURES THERMOSTAT REPLACEMENT Thermostat Figure 1 Thermostat Location The Thermostat is located to the left of the Condenser as shown in Figure 1 1 Disconnect unit from its power source 2
12. o a lower number for a warmer temperature Replace thermostat Clear drain hose Tighten or connect drain hose AN WARNING THE POWER MUST BE TURNED OFF AND DISCONNECTED AT ALL TIMES DURING MAINTENANCE OR REPAIR FUNCTIONS MAINTENANCE STAINLESS STEEL CARE AND CLEANING Stainless steel contains 70 80 iron which will rust It also contains 12 30 chromium which forms an invisible passive film over the steel surface and acts as a shield against corrosion As long as the protective film remains intact the metal will not corrode However if the film is broken or contaminated outside elements can begin to breakdown the steel and begin to form rust or discoloration To prevent rust and discoloration on stainless steel several important steps need to be taken CAUTION Never use steel wool pads wire brushes scrapers Avoid cleaning solutions that contain alkaline or chloride 10 Use non alkaline based or non chloride cleaning solutions Anything containing chloride will damage the protective film on stainless steel Chlorides are found in household and industrial cleaners and also in hard water and salts If a chloride or alkaline cleaner has been used rinse repeatedly and dry thoroughly Always use only soft cloths or plastic scouring pads Use warm soapy water for routine cleaning Anon abrasive cleanser may be used on stubborn stains For heavy grease use a degreaser For best results
13. o the tags to reattach the evaporator tubing to Refrigeration Assembly 13 Refer to the tags to reconnect the wiring at the junction box 14 Connect the unit to its power source and test its operation 15 Charge the system according to Duke Manufacturing Service Bulletin Number 26 16 Install the vent cover DRAIN REPLACEMENT Figure 4 Drain Location The purpose of the drain is to drain evaporator condensate and ice melt only Do not pour food product down the drain 1 Remove the unit from its power source 2 Disconnect PVC tubing from the PVC barb 3 Remove the PVC barb and reducer from the drain NOTE On AHC Aerohot Salad Bar models the Globe valve must also be removed Me Mechanically Cooled Buffets and Salad Bars Remove the large nut and gasket that secure the drain to the pan 5 Push the drain from the bottom up 6 Clean all remaining drain sealer and gasket material from the top and bottom of the pan Place a bead of drain sealer around the bottom edge of the new drain Place the drain into the drain hole in the pan Drain Sealer 10 11 12 13 14 15 Gasket Figure 5 New Drain Assembly Place the gasket if provided over the drain down tube Replace the securing nut CAUTION Do not overtighten the drain Replace the reducer Globe valve AHC models only and PVC barb Inspectthe PVC tubing for damage and replace as needed Remove excess drain seale
14. r from around the drain Ensure that there are no leaks Reconnect the unit to its power source PLEXIGLAS CANOPY REPLACEMENT Economate and Aerohot Salad Bars Figure 6 Plexiglas Canopy The Plexiglas Canopy is mounted to the canopy brackets using rubber grommets 1 Disconnect unit from power source 2 Remove the screws that hold the canopy on as depicted in Figure 6 NOTE If canopy bracket replacementis required they can be removed once the Plexiglas Canopy is removed 3 Remove the rubber grommets from the old Canopy 4 Remove the protective plastic covering from the new canopy Install rubber grommets in the new canopy Install the new canopy NOTE Install new canopy brackets first if replacing them CAUTION Do not overtighten the screws Over tightened screws will crack the Plexiglas 7 Connect the unit to its power source Mechanically Cooled Buffets and Salad Bars CASTER REPLACEMENT Economate Figure 7 Economate Casters Economate units are supplied with NSF listed 5 casters Two casters are provided with locks 1 2 3 4 o Disconnect the unit from its power source Remove the unit from its base Turn the base upside down Remove the four bolts securing the caster to the base Remove the caster Replace the caster with a new one NOTE Casters with brakes must be replaced with brake units 7 Tighten all four mounting bolts Turn the base
15. rub with the grain of the steel Pitting and cracking are early signs of stainless steel breakdown Special stainless steel cleaners can restore and preserve the protective film If signs of breakdown appear thoroughly clean and dry all surfaces Begin regular application of a high quality stainless steel cleaner according to the manufacturer s instructions Again always rub with the grain of the steel for best results CAUTION Never use an acid based cleanser Be sure to clean all food products from any AY stainless surface Many food products contain acid which can deteriorate the finish Common acidic foods include tomatoes peppers and other vegetables CARE AND CLEANING PAINTED OR POWDER COATED UNITS Paint and Powder Coat are applied finishes They are applied to a paint ready steel surface Like stainless steel units with these coatings should be cleaned with mild soap and a soft cloth Stubborn stains can be removed with a plastic scrubbing pad Never use abrasive materials to clean painted or powder coated surfaces After cleaning with mild soap and a soft cloth painted and powder coated surfaces must be rinsed with warm water and a soft cloth to remove soap residue Always wipe painted or powder coated surfaces dry with a soft dry cloth after cleaning CLEANING THE CONDENSER COIL Figure 9 Condenser Coil Location Failure to maintain a clean condenser coil can cause high temperatures and ex
16. unit right side up and reinstall the warmer assembly Reconnect the unit to its power source Heritage Thurmaduke amp AHC Duke Salad Bar Models 4 A Mounting screws Figure 8 Thurmaduke Casters Thurmaduke Serving Systems AeroServ Serving Systems and Heritage models are supplied with NSF listed 5 black swivel casters Each unit is supplied with a pair of locking casters 1 2 Disconnect the unit from its power source Make sure the pans have been emptied of all content Raise and support the side of the unit that requires a new caster Remove the four mounting bolts Remove the caster Replace the caster Always replace locking casters with locking casters Reattach and tighten the mounting bolts Remove the unit from the support Reconnect the unit to its power source Me Mechanically Cooled Buffets and Salad Bars RECHARGING REFRIGERATION SYSTEM To analyze the performance of a refrigeration system temperature readings are recorded and converted to pressure readings using a standard pressure temperature chart Strictly adhere to the following approved procedure when it is necessary to service a factory sealed refrigeration system TOOLS Standard hand and refrigeration tools Refrigerant Type R 134A 4 5 ounces CHARGING PROCEDURE NOTE Priorto refrigeration system service special care must be taken during the evacuation process to remove air moisture and other non condens
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