Service Manual 06/2004
Contents
1. AN10507300 1 TERM BLOCK ASSY MSR 7 TF0052 1 TRANSFORMER 208 240 12 20VA 8 CP0105 1 CONTROLLER DIGITAL 3 WELL 9 SCR469 8 SCREW 6 32 X 3 16 SLT 10 SP0042 4 SPACER 6 32 X 3 8 PLASTIC NYLON Wiring Diagrams Waterless Drop In Merchandiser Wiring Diagrams 5 325 UDNY 594 40 1007 8 OHO 325 ADNIA 539 50 ON 3201 61505 7052 VSI 1540 2 5 83004 5 750041 035 2071 A0 Z 90Z HINYOISNWAL 000 9092 0001 INGNGT3 9NUV3H y 002 ABOZ MOOOL ININTIG 9 6 10 04 2 AVIY ANNDUIN Z 4 1 A0T A mM Nana 5 AOZ u sa 70007 ABOZ 11 Ka mooot CION LIN3N313 931 39NY8O OL 123 02 ADOPT 931 035 OL 123 09 AGOZ 10 Waterless Drop In Merchandiser Wiring Diagrams BREAKER SIZE 20 or 15 HEATER CONNECTIONS CONNECT TO RED LEG 40 CONNECT TO ORANGE LEG FOR FOR 8 FE 7 iR VIEWED FROM REAR WITH PANEL HINGED DOWNWARD OPERATOR CONTROL PANEL MODEL No DRPN 3TB RELAY CONTROL BOX SHOWN FOLDED FLAT PPROVED 8 DATE ou v 11 Waterless Drop In Merchandiser Appendix A Digital Controller Information Appendix A Digital Controller Information Turning Controller On and Off Hold CTRL RESET down for 20 seconds to turn control2. Damage 5 Installation ed Sind 5 Electrical Information 5 Replacement Parts ic lt a 6 Well Assembly 6 Control Box 8 Wiring Diagrams u uu u a au uma w 10 Appendix Digital Controller Information l l 12 Turning Controller On and Off 12 Reading th DISp 8y u u Su duces cece n sasa spissa 12 Programming Temperature 12 Historical Duty 12 Error usu su uhun dies Lennie 13 Waterless Drop In Merchandiser Introduction Introduction Congratulations You have chosen a Waterless Drop In Merchandiser It consists of one or more hot food waterless wells and a digital controller for setting monitoring and controlling the temperature of each well This unit is manufactured by BKI which assures you of the finest in design and engineering that it has been built with care and dedication using the best materials available Attention to the operating instructions regarding proper installation operation and maintenance will result in long lasting dependability to insure the highest profit
3. crates or cartons or if a shortage is found note this on the bill of lading all copies before signing If damage is detected when the equipment is uncrated immediately call the delivering truck line and follow up the call with a written report indicating concealed damage to your equipment Ask for an immediate inspection of your concealed damage item Crating material MUST be retained to show the inspector from the truck line Installation Instructions 1 Obtain a suitable countertop location for the unit 2 Cuta hole in the countertop measuring 41 7 16 x 24 3 8 3 Orient the unit for proper positioning of the controller then carefully lower unit into the cutout area 4 Wire the unit according to the guidelines below 5 Seal the countertop to conform to NSF Standard 4 4 28 Dow Corning RTV 732 Multi purpose Sealant Electrical Information AWARNING Electrocution equipment failure or property damage could result if an unlicensed electrician performs the electrical installation Ensure that a licensed electrician perform the electrical installation in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 20XX This unit when installed by an authorized service agent must be wired for use in accordance with all applicable local state and federal codes For specific electrical requirements and connections refer to the wiring diagram attached to the un
4. 0400 Simpsonville S C 29680 0400 Or call toll free 1 800 927 6887 Outside the U S call 864 963 3471 Waterless Drop In Merchandiser Introduction x 911 Be Prepared for Emergencies Be prepared for fires injuries or other emergencies Keep a first aid kit and a fire extinguisher near the equipment You must use a 40 pound Type BC fire extinguisher and keep it within 25 feet of your equipment Keep emergency numbers for doctors ambulance services hospitals and the fire department near your telephone Know your responsibilities as an Employer e Make certain your employees know how to operate the equipment e Make certain your employees are aware of the safety precautions on the equipment and in this manual e Make certain that you have thoroughly trained your employees about operating the equipment safely e Make certain the equipment is in proper working condition If you make unauthorized modifications to the equipment you will reduce the function and safety of the equipment Waterless Drop In Merchandiser Installation Installation AWARNING Serious injury equipment damage or death could result if attempting to install this unit yourself Ensure that an authorized BKI service agent installs the unit Instructions For Shipping Damage You are responsible for filing all freight claims with the delivering truck line Inspect all cartons and crates for damage when they arrive If there is damage noted to shipping
5. AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED ARE EXCLUDED INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE THIS WARRANTY SHALL APPLY ONLY WITHIN THE CONTINENTAL UNITED STATES ITS TERRITORIES AND POSSESSIONS AND IN CANADA LIMITED NINETY DAY LABOR WARRANTY All labor necessary to repair or replace factory defective parts will be performed without charge to the end user by service personnel of Authorized Distributor during the first ninety days after the date of installation of the new equipment Replacement parts Any appliance replacement part except lamps and fuses which proves to be defective in material or workmanship within 90 days from date of original installation will be repaired or replaced without charge F O B Factory Simpsonville S C or F O B authorized distributor Waterless Drop In Merchandiser Table of Contents Table of Contents Table of Contents 1 u u E 2 Safely amp 2 Safety Signs and Messages 2 Safe Work PracglIlees uu u seabed 3 ON 5 Instructions For Shipping
6. Waterless Drop In Merchandiser MODELS DRPN1 DRPN5 DRPN7 Service Manual Serial Numbers 122157 and Higher Fresh ideas in foodservice equipment Warranty Information LIMITED ONE YEAR WARRANTY The warrants to the original purchaser user that at time of shipment from the Company factory this equipment will be free from defect in materials and workmanship Written notice of a claim under this Warranty must be given within ONE YEAR AND THREE MONTHS from date of shipment from the factory Defective conditions caused by abnormal use or misuse lack of maintenance damage by third parties alterations by unauthorized personnel acts of God failure to follow installation instructions or any other events beyond the control of the company will NOT be covered under Warranty The obligation of the Company under this Warranty shall be limited to repairing or replacing at the option of the company any part that is defective in reasonable opinion of the Company The user will have the responsibility and expense of removing and returning the defective part to the Company as well as the cost of reinstalling the replacement or repaired part IN NO EVENT SHALL THE COMPANY BE LIABLE FOR LOSS OF USE LOSS OF REVENUE OR LOSS OF PRODUCT OR PROFIT OR FOR INDIRECT OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO FOOD SPOILAGE OR PRODUCT LOSS WARRANTY DOES NOT COVER GLASS BREAKAGE THE ABOVE WARRANTY IS EXCLUSIVE
7. able return on your investment NOTICE PLEASE READ THIS ENTIRE MANUAL BEFORE OPERATING THE UNIT If you have any questions please contact your BKI Distributor If they are unable to answer your questions contact the BKI Technical Service Department toll free 1 800 927 6887 Outside the U S call 1 864 963 3471 This unit is to be sealed to the surface where installed to conform to NSF requirements Dow Corning RTV 732 Multi purpose Sealant Safety Precautions Always follow recommended safety precautions listed in this manual Below is the safety alert symbol When you see this symbol on your equipment be alert to the potential for personal injury or property damage Safety Signs and Messages The following Safety signs and messages are placed in this manual to provide instructions and identify specific areas where potential hazards exist and special precautions should be taken Know and understand the meaning of these instructions signs and messages Damage to the equipment death or serious injury to you or other persons may result if these messages are not followed ADANGER This message indicates an imminently hazardous situation which if not avoided will result in death or serious injury AAWARNING This message indicates a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION This message indicates a potentially hazardous situation which if not avoided may r
8. d will not release Gently push on the Set button and attempt to free the button Have service re adjust the board distance to the button CONTROLLER NONE Xd One or more temperature probes have failed or are out of calibration The unit is now running in safe mode called historical duty cycle mode The unit will run at approximately the same temperature as it did when the temperature probe was present TEMPERATURE PROBE NONE 113 DrY Startup sequence display for X3 control identifier and 3 element dry well configuration NONE OFF Reset button has been held down for 20 seconds thus turning off controller Push reset button to start back up NONE HUP System is heating up Heat up can take up to an hour depending on the elements of your system 13 BKI P O Box 80400 Simpsonville S C 29680 0400 USA http www bkideas com Made and printed in the U S A LI0271 0604
9. emperature probes broken and intermittently touching TEMPERATURE PROBES WIRES CONTROLLER YELLOW TC1 TC2 and or TC3 Temperature probe is outside its standard calibration and heat cycle times System will default into Historical Duty Cycle Mode Turn on off unit to see if the problem comes back If so call for service TEMPERATURE PROBE ELEMENTS YELLOW 0 1 0 2 or 0 3 Thermocouple that is used by the display has been disconnected or broken Probe wire may have been cut pulled on or temperature probe needs to be replaced TEMPERATURE PROBE NONE RED CCC Set and Up buttons are stuck down and will not release Gently push on the Set and Up buttons and attempt to free the buttons Have service re adjust the board distance to the buttons CONTROLLER NONE RED NONE RED HI UP Lo DN Up button is stuck down and will not release Gently push on the Up button and attempt to free the button Have service re adjust the board distance to the button CONTROLLER Down button is stuck down and will not release Gently push on the Down button and attempt to free the button Have service re adjust the board distance to the button CONTROLLER NONE RED rLo RES Reset button is stuck down and will not release Gently push on the Reset button and attempt to free the button Have service re adjust the board distance to the button CONTROLLER NONE RED Slo SET Set button is stuck down an
10. esult in minor or moderate injury It may also be used to alert against unsafe practices NOTICE This message is used when special information instructions or identification are required relating to procedures equipment tools capacities and other special data Waterless Drop In Merchandiser Introduction Safe Work Practices Beware of High Voltage This equipment uses high voltage Serious injury can occur if you or any untrained or unauthorized person installs services or repairs this equipment Always Use an Authorized Service agent to Service Your Equipment Keep this manual with the Equipment This manual is an important part of your equipment Always keep it near for easy access If you need to replace this manual contact Technical Services Department P O Box 80400 Simpsonville S C 29680 0400 Or call toll free 1 800 927 6887 Outside the U S call 864 963 3471 Protect Children Keep children away from this equipment Children may not understand that this equipment is dangerous for them and others NEVER allow children to play near or operate your equipment Keep Safety Labels Clean and in Good Condition Do not remove or cover any safety labels on your equipment Keep all safety labels clean and in good condition Replace any damaged or missing safety labels If you need a new safety label obtain the number of the specific label then contact BKI Technical Services Department P O Box 8
11. it or provided in the Service Manual Waterless Drop In Merchandiser Replacement Parts Replacement Parts Use the information in this section to identify replacement parts To order replacement parts call your local BKI sales and service representative Before calling please note the serial number on the rating tag affixed to the unit Well Assembly Components 0 fk i Waterless Drop In Merchandiser Replacement Parts FRONT ACCESS ITEM PART DESCRIPTION 1 C0034 CALROD 208V 1000W C0035 CALROD 240V 1000W 2 FB66238009 ELEMENT ENCLOSURE 3 SCR133 SCREW 10 24 X 1 2 HEX CAP 4 FB66236009 ACCESS PLATE 5 FB66252909 HEATING ELEMENT COVER W TAB 6 FB67642409 THERMOBULB NEST WDC 7 NUT076 NUT 10 24 PALNUTS 8 FB66236209 ELEMENT COVER END DRPN 3TB FB66236309 ELEMENT COVER CTR DRPN 3TB 9 FB66237909 COVER ELEMENT CVR END DRPN 3TB FB66237809 COVER ELEMENT CVR CTR DRPN 3TB 10 WSH037 WASHER 3 16 SAE FLAT 11 WSH246 WASHER 10 INT TOOTH S S Waterless Drop In Merchandiser Replacement Parts Control Box Assembly Waterless Drop In Merchandiser Replacement Parts PART QTY DESCRIPTION 1 0537 1 DECAL DRPN 3TB W UMC X3 2 FH0001 2 FUSE HOLDER 15A 300V HPF EE 3 F0144 2 FUSE 5A 600V SC5 BUSSMAN 4 R0139 3 RELAY MERCURY 2 POLE 5 S0319 1 SWITCH DPST 15 250V 6
12. ler off The display shows OFF Press CTRL RESET to turn controller on Upon start up or reset sequence display shows 3 then DrY Reading the Display The wells are numbered from left to right The display will cycle through well number 1 2 3 then the corresponding temperature of well The display contains three 3 decimal points The decimal points turn on and off to denote elements cycling The heat light turns on if any element is on Programming Temperature Setpoints Pressing and holding the TEMP SET button will cause the controller to beep and the display will intermittently flash between the well number and the programmed setpoint temperature To adjust setpoint temperature hold TEMP SET down and press UP or DOWN arrows to adjust temperature Each press of the UP or DOWN arrow will adjust the setpoint temperature one increment Press and hold the UP or DOWN arrow to increment rapidly To change well setting hold TEMP SET down and press RESET The display will intermittently flash the well number 1 2 3 Each additional press of RESET will increment the well number Historical Duty Cycle The controller is equipped to operate temporarily with the loss of one or more temperature probes or with temperature probes out of calibration When the unit is operating in historical duty cycle mode the unit will run at the approximate equivalent temperatures as when temperature probes were functional To deno
13. te that the unit is functioning in historical duty cycle mode the display will cycle with well number then 20d or some number with d instead of a temperature To adjust the setpoint when in historical duty cycle hold TEMP SET down and press UP or DOWN arrows to adjust the setpoint Each press of the UP or DOWN arrow will adjust the setpoint one increment Press and hold the UP or DOWN arrow to increment rapidly 12 Waterless Drop In Merchandiser Error Codes Appendix A Digital Controller Information FLASHER ERROR CODE PROBLEM DESCRIPTION SERVICE PARTS RED Combination of codes below Multiple failures have occurred and have caused a critical situation RED This means a piece of equipment needs immediate attention because it cannot hold its temperature or an alternative backup plan needs to be started RED r1F r2F and or r3F All Elements Off Heating element or contactor has failed to turn on or all elements have failed to turn on Turn off power and breakers and then turn them back on Call for service immediately if this does not work and all error codes display HEATING ELEMENT FUSE ON OFF SWITCH MERCURY RED r1O r2O and or All Elements On Element s are stuck on Turn power switch and breaker off then back on If problem persists call for service The problem could be shorted wires inside unit It could also be a temporary side effect of t
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