Service Manual ELECTRIC SEALED WELL FOOD WARMERS
Contents
1. sess 6 Aerohot ASI1SW through ASISSW 2 6 Thurmaduke Steam Tables and Thurmaduke Serving Systems 7 Indicator Lamp nennen nnne 8 Power Toggle Switch Replacement Thurmaduke 9 Element Replacement sse nennen nnne nne nenne nennen nnn 9 Hi Limit Thermostat Replacement 10 Carving Board Shelf ReplacBIisnil tatu ud 11 Caster Replacement Thurmaduke Serving System AeroServ and Heritage 12 Push Bar Replacement Thurmaduke Serving 12 Master Drain Valve 13 SERVICE INFORMATION s E a ES 15 Troubleshooting Procedure me 15 5555555 16 Stainless Steel Care and Cleaning arces ente naa nn tape tk eua 16 Care and Cleaning Painted and Powder Coated 16 SCHEMATICS cM E 17 Service Manual for Electric Sealed Well Food Warmers Mmm SPECIFICATIONS MODEL DESCRIPTION VOLTAGE SIZE E302SW E305SW Aerohot Sealed2. weight For the most efficient operation be sure to provide good air circulation inside and out Leveling Be sure floor units are placed on a firm flatsurface 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 Level the unit accordingly using the leg adjusters Make sure the top of the cabinet is level before installing Aerohot drop in or slide in units It may be necessary to shim the unit or cabinet to make it level Stabilizing Use the leg adjustments to ensure that the unit is solid to the floor surface at all contact points Ensure that the unit does not rock when pressure is applied to the top corners Units with casters will require spacers to make them level on uneven 4 surfaces The spacers should be placed under the locking casters for maximum stability Casters must be locked when the unit is in service Electrical Connection The Electric Sealed Well Food Warmers are available as 115VAC 208VAC or 236VAC 50 60 Hz Portable units are available with a properly rated and wired cord Direct wiring of units to the power supply must be performed by a certified electrician and must comply with local electrical codes for your municipality WARNING REFER TO THE AMPERAGE DATA LIST IN THE SPECIFICATIONS OR THE SERIAL TAG DATA AND YOUR LOCAL CODE OR THE NATIONAL ELECTR
3. Well 115VAC 208VAC amp 236VAC Variable 2 well to 5 well ADITESW ADISESW Aerohot Drop in Sealed Well 115VAC 208VAC amp 236VAC Variable 1 well to 5 well ASITESW ASIBESW Aerohot Slide in Sealed Well 115 VAC 208VAC amp 236VAC Variable 1 well to 5 well E 2 CBSS E 6 CBSS Stainless Steel Thurmaduke 115VAC 208VAC amp 236VAC Variable 2 well to 6 well E 2 CBPG E 6 CBPG Painted Thurmaduke 115VAC 208VAC amp 236VAC Variable 2 well to 6 well E302 25 E305 25 AeroServ Serving System 115 VAC 208VAC amp 236 Variable 2 well to 5 well HB2HF HB5HF Heritage Buffet 115VAC 208VAC amp 236VAC Variable 2 well to 5 well TEHF 32 TEHF88 Thurmaduke Serving System 115VAC 208VAC amp 236VAC Variable 2 well to 6 well NG32HF NG74HF Next Generation Hot Food 115 208VAC amp 236VAC Variable 2 well to 5 well INSTALLATION Location The food warmers represented in this manual are intended for indoor use only Be sure the chosen location has a floor strong enough to support the total weight of the unit fully loaded with food product Reinforce the floor stationary units or cabinet drop in or slide in units if necessary to provide for maximum loading Portable units units with optional casters should be placed on a level surface capable of supporting the unit s fully loaded
4. the push bar from painted 1 Disconnect the unit from its power source 9 models to prevent scratching or peeling of paint 2 Make sure pans are drained 5 Insert new push bar into handle holes in the unit Reattach washers and nuts Reattach any wires that were disconnected when the bottom cover was removed Reinstall the bottom cover Connect the unit to its power source Hold fitting steady with a properly sized wrench Figure 22 Master Valve and Valve Fitting 3 Remove the old valve 13 Service Manual for Electric Sealed Well Food Warmers Mmmm Caution The valve may be very tight It is 4 Apply pipe sealer pipe dope to the threads important to hold the pipe fitting of the new valve ae see Figure 22 with a wrench of 5 Screw the new valve onto the pipe fitting on the manifold Make sure it is tight but do not overtighten it the proper size connected to the coupler to prevent damage to the plumbing Copper is a very soft material and will bend PVC is 6 Test the valve for leaks Tighten as brittle and breaks very easily necessary 7 Reconnect the unit to its power source 14 ENS Service Manual for Electric Sealed Well Food Warmers SERVICE INFORMATION TROUBLESHOOTING PROCEDURE SYMPTOM CAUSE REMEDY Element does not heat Unit not plugged in No power to unit Defective thermostat or infinite switch Open hi limit thermostat Open element Unit not level wobble
5. ICAL CODE TO BE SURE UNIT IS CONNECTED TO THE PROPER POWER SOURCE 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 Service Manual for Electric Sealed Well Food Warmers PARTS REPLACEMENT A WARNING ALWAYS DISCONNECT THE UNIT FROM ITS POWER SOURCE BEFORE INFINITE SWITCH REPLACEMENT Aerohot Sealed Well Models AeroServ Serving System Heritage Hot Food Electric Buffet and Next Generation Electric Hot Food Serving System Figure 1 Location of Infinite Switch Infinite switches are located on the operator s side ofthe unit Each switch is located directly below its corresponding pan Figure 1 depicts the location of the switches on most sealed well units 1 Disconnect unit from power source Remove 4 screws Figure 2 Removing bottom cover 2 Remove the screws that hold the bottom cover in place see Figure 2 3 Slide the bottom cover toward the back of the unit Provide support for it to prevent damage to the wiring harness Note Tag the power cable wires and disconnect them Doing this allows for complete removal of the bottom cover Locking t D1024 Figure 3 View of infinite switch wiring 4 Tag and disconnect the infinite switch wiring An example
6. R DEATH WARNING DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE WARNING DO NOT OPERATE THIS EQUIPMENT WITHOUT PROPERLY PLACING AND SECURING ALL COVER AND ACCESS PANELS CAUTION Observe the following Provide and maintain adequate minimum clearances from all walls and combustible materials e Provide and maintain adequate clearance for air openings Keep the equipment area free and clear of combustible material Operate equipment only on the type of electricity indicated on the specification plate e Retain this manual for future reference Service Manual for Electric Sealed Well Food Warmers TABLE OF CONTENTS SPECIFICATIONS ego vv nl a bove t uet do a 4 INSTALLATION RM Eee 4 LOCALON M U Uu 4 ES NG ssr ena ea RN UM MUS dra MUN I AUAM ua deep Llnt IxMD GR MET etd 4 SUA ERE RD I TUE 4 Electrical Connection ee 4 PARTS REPLACEMENT 5 Infinite Switch 2 01 1 2 2220 6 000000000000 eene nennen nnne 5 Aerohot Sealed Well Models AeroServ Serving System Heritage Hot Food Electric Buffet and Next Generation Electric Hot Food Serving System 5 Aerohot ADI1SW through ADISSW 5 2222 6 Electronic Thermostat Replacement
7. Service Manual ELECTRIC SEALED WELL FOOD WARMERS MODELS THURMADUKE STEAM TABLES THURMADUKE SERVING SYSTEMS AEROHOT SEALED WELL MODELS AEROSERV SERVING SYSTEMS u HERITAGE HOT FOOD ELECTRIC BUFFET NEXT GENERATION ELECTRIC HOT FOOD SERVING SYSTEMS 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 Written consent from Duke is required to reproduce any portion of this Manual Unauthorized reproduction is prohibited Duke Manufacturing Company Broadway St Louis MO 63102 800 735 3853 314 231 1130 www dukemfg com P N 219219B Service Manual for Electric Sealed Well Food Warmers Mmm 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 O
8. bottom cover 15 Connect the unit to its power source HI LIMIT THERMOSTAT REPLACEMENT All Models High limit Lock Thermostat Nut Figure 13 Location of the Hi Limit Thermostat The hi limit thermostatic switch is located on the bottom of each pan next to the element wire connections It is connected directly to the sealed pan as depicted in Figure 13 1 Disconnect unit from power source 2 Remove the bottom cover as depicted in Figure 2 Note Tag and disconnect the power wires set the bottom cover aside for reassembly Tagthe wires to the hi limit thermostatic switch and disconnect them 4 Remove the lock nut that holds the hi limit thermostat in place and lift the hi limit thermostatic switch off of its mounting stud 5 Placethenewhi limitthermostatic switch onto the mounting stud 6 Replace the lock nut Caution AN 7 Reference the tags to reconnect the hi limit thermostatic switch wiring Do not overtighten the lock nut Overtightening will damage the hi limit thermostat 8 Reconnect the power wires and install the bottom cover 9 Connect the unit to its power source CARVING BOARD SHELF REPLACEMENT All Models Carving Board Shelf D1035 Figure 14 Location of Carving Board Shelf The carving board and carving board shelf are located on the server s side of the unit as depicted in Figure 14 If needed the carving board is replaceable as a separate unit Aer
9. f Thermostat Thurmaduke models Thermostats are located on the operator s side of the Thurmaduke models as depicted in Figure 6 Each thermostat is mounted directly below the sealed pan it controls 2 Disconnect unit from power source Remove the screws that hold the bottom cover see Figure 2 in place Slide the bottom cover toward the back of the unit Provide support for it to prevent damage to the wiring harness Note Tag the power cable wires and disconnect them Doing this allows for complete removal of the bottom cover 4 Tag and disconnect the thermostat wiring Remove the knob guard The knob guard is held on by two locking nuts on the inside of the front panel Remove the knob Remove the screws securing the thermostat to the panel Service Manual for Electric Sealed Well Food Warmers 8 Remove the thermostat from the back of the panel 9 Install replacement thermostat mounting screws knob and knob guard 10 Reference the tags to reconnect the wires to the thermostat 11 Reconnect the power wires and reinstall the bottom cover 12 Connect the unit to its power source INDICATOR LAMP REPLACEMENT All Models Except ADI Areohot Models A Indicator Lamp Figure 7 Location of Pan Indicator Lamp The pan indicator lamp is located on the control panel above the infinite switch or electronic thermostat on all electric units as depicted in Figure 7 The lamp is
10. h is located on the operator s control panel to the right of the power indicator lamp as depicted in Figure 9 1 Disconnect unit from power source 2 Removethe screwsthathold the bottom cover in place see Figure 2 3 Slide the bottom cover toward the back of the unit Provide support for it to prevent damage to the wiring harness Note For easier access tag power cable wires then disconnect and remove the bottom cover 4 Tag and disconnect the power toggle wiring 5 Remove the toggle switch It may be held in place by crimp springs screws or a spin nut on the toggle shaft Toggles that are held in by screws or a spin nut will be removed from the rear of the panel Toggles held in place by crimp springs will be removed by squeezing the crimp springs and pushing the toggle out through the front of the panel Service Manual for Electric Sealed Well Food Warmers Install replacement toggle switch Reference the tags to reconnect the wires to the toggle switch 8 Reconnect the power wires and reinstall the bottom cover 9 Connect the unit to its power source ELEMENT REPLACEMENT All Models Element Pan Element Figure 10 Location of heat elements The heat element is located under each pan and is housed in an element pan for protection as depicted in Figure 10 Use replacement elements that are rated for the model being serviced 1 Disconnect unit from power source Note Drop in and slide in uni
11. lit when the pan is in operation Thurmaduke models are equipped with a power on indicator lamp located next to the power toggle switch on the operator s right side 1 Disconnect unit from power source Note Slide in and drop in units must be removed from their cabinets 2 Removethe screws thathold the bottom cover in place 3 Slide the bottom cover toward the back of the unit and lift it out as depicted in Figure 2 Indicator White wires to Indicator Lamp Figure 8 Inside of panel showing location of pan indicator lamp 4 PanlndicatorLamps Disconnectthe indicator lamp wiring from the infinite switch or electronic thermostat as depicted in Figure 8 Power Indicator Lamp Thurmaduke models only Disconnect the indicator lamp wires from the back of the power toggle switch 5 Remove the indicator lamp assembly The lamp is held in place by crimp springs 6 Replace the indicator lamp assembly 7 Replace the lamp with a new one Note If the lamp assembly is held on by a nut the nut must be screwed on prior to reattaching the lens 8 Reconnect the indicator lamp wiring 9 Reconnect the power wires and install the bottom cover 10 Connect the unit to its power source POWER TOGGLE SWITCH REPLACEMENT Thurmaduke Models Figure 9 Location of power toggle switch on all Thurmaduke models All Thurmaduke models are equipped with a power toggle switch The switc
12. mostats or Infinite Switches 17 Service Manual for Electric Sealed Well Food Warmers Mmmm NOTES 18 Service Manual for Electric Sealed Well Food Warmers 19 Service Manual for Electric Sealed Well Food Warmers BEEN Duke Manufacturing Company Broadway St Louis MO 63102 800 735 3853 314 231 1130 www dukemfg com 20 P N 219219B
13. n caster flange 5 Slide the old caster off of the leg channel 6 Line up the holes in the caster flange with the mounting holes in the leg channel 7 Slide the new caster into position Always replace locking casters with locking casters 8 Reattach and tighten the mounting screws 9 Remove the unit from the supports 10 Reconnect the unit to its power source PUSH BAR REPLACEMENT Thurmaduke AeroServ and Heritage Serving Systems Figure 19 Push bar on Thurmaduke Serving Systems Push bars are mounted on the side of the serving system that has the locking casters Generally this is the operator s right side Push bars are optional with the Thurmaduke Heritage and AeroServ Serving Systems 1 Remove the unit from its power source 2 Remove the bottom cover as depicted in Figure 2 Service Manual for Electric Sealed Well Food Warmers MASTER DRAIN VALVE REPLACEMENT Retaining Retaining Nuts Screws All Models 7 A 1 Figure 20 View of Push Bar retaining nuts screws Figure 21 Location of Master Drain Valve 3 Remove the retaining nuts and washers from All sealed well units are provided with a drain the push bar studs system The drain system may be provided in copper or PVC depending on the model The master drain valve is located below the drain manifold as depicted in Figure 21 4 Gently pull the push bar free of the unit Caution Be very careful when removing
14. ofthe infinite switch wiring is seen in Figure 3 Service Manual for Electric Sealed Well Food Warmers Mmmm 5 Remove the knob 6 Removethe two screws that secure the infinite switch to the panel 7 Remove the switch from the back of the panel 8 Install replacement infinite switch mounting screws and knob 9 Reference the tags to reconnect the wires to the infinite switch 10 Reconnect the power wiring and reinstall the bottom cover 11 Connect the unit to its power source Aerohot ADI1SW through ADISSW Models Remote Infinite Switch Figure 4 Location of Infinite Switch Aerohot Drop in ADI models Infinite switches are located in a separate control panel that is mounted to the front of the cabinet Figure 4 depicts an uninstalled ADI unit with the remote infinite switch control panel 1 Disconnect unit from power source 2 Remove the screws that hold the unit and its remote infinite switch controller in the cabinet 3 Pullthe remote infinite switch controller out of the cabinet for servicing 4 Remove screws holding the back cover of the remote infinite switch control panel in place 5 Tag and disconnect the infinite switch wiring Wiring is depicted in Figure 3 6 Remove the knob 7 Remove infinite switch mounting screws 8 Remove the infinite switch from the remote control panel 9 Install replacement infinite switch mounting screws and knob 10 Reference the tags to
15. ohot Drop in and Slide in units are not available with carving boards 1 on oa Service Manual for Electric Sealed Well Food Warmers Carving board Carving board mounting stud D1036 Figure 15 Carving board mounting stud Lift the carving board off its mounting studs as depicted in Figure 15 Figure 16 Carving board shelf mounting brackets Loosen the top screw in the slotted hole at the top of the bracket on both sides of the unit as depicted in Figure 16 Remove the rest of the screws that hold the shelf on the unit Lift the shelf up and away from the unit Replace the shelf with the new one Reinstall the screws Tighten the screws in the slotted holes Insertthe new carving board onto the mounting studs on the shelf 11 Service Manual for Electric Sealed Well Food Warmers Mmm CASTER REPLACEMENT Thurmaduke Serving System AeroServ and Heritage Models Figure 17 Units with casters Thurmaduke AeroServ and Heritage models are supplied with NSF listed 5 black swivel casters Each unit is supplied with a pair of locking casters Disconnect the unit from its power source 2 Make sure pans have been completely emptied 3 Raise and support the side of the unit that requires a new caster 4 Remove the four screws that hold the caster to the channel at the bottom of the unit Mounting screws 12 Figure 18 Location of mounting holes o
16. rasive materialsto 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 they are cleaned WARNING THE POWER MUST BE TURNED OFF AND DISCONNECTED AT ALL TIMES DURING MAINTENANCE OR REPAIR FUNCTIONS ENS Service Manual for Electric Sealed Well Food Warmers SCHEMATICS L1 n gee o ay H9 L2 C o S P 4 Ly P Ly Ly 1 1 5 ewe AM Single Phase 120VAC to 240VAC with Infinite Switch L1 C Pan eoe ci N 5 5 Single Phase 120VAC to 240VAC with Thermostatic Control L1 So cQ EM L2 o lt L3 e 3 l S SJ G H L U ON 5 Loy Three Phase 120VAC to 240VAC with Infinite Switch Tanta ere ears ya r E l T Ji Three Phase 120VAC to 240VAC with Thermostatic Control Figure 23 Schematics of Sealed Well Units with Electronic Ther
17. reconnect the wires to the infinite switch 11 Reinstall the back cover of the remote infinite switch control 12 Reconnect the power wires and reinstall the unit into the cabinet 13 Connect the unit to its power source THERMOSTAT REPLACEMENT Aerohot ASI1SW through ASIBSW Models Thermostats Figure 5 Location of Thermostat Aerohot Slide in ASI models Thermostats are located in front on the control panel below each pan Figure 5 depicts the location of the thermostat 1 Disconnect the unit from its power source 2 Slide the unit out of its cabinet 3 Turn the unit upside down and remove the screws that hold the bottom cover in place ENS Service Manual for Electric Sealed Well Food Warmers o go Slide the bottom cover toward the back of the unit and lift it out as depicted in Figure 2 Tag and disconnect the thermostat wiring Remove the knob Remove the thermostat mounting screws Remove the thermostat and sensor probe Install the thermostat probe into the slide in tube in the pan Note Do not kink the thermostat probe when 10 11 12 13 14 reinstalling it Install the new thermostat mounting screws and knob Reference the tags to reconnect the wiring to the thermostat Install the bottom cover Slide the unit back into its cabinet Connect the unit to its power source Thurmaduke Steam Tables and Thurmaduke Serving Systems Figure 6 Location o
18. s Legs not adjusted properly floor models Cabinet not level drop in or slide in units Master valve leaks Compression fitting not tight enough Wells will not drain Valve mechanism worn Master valve closed Master valve clogged Valve handle moves but does not open valve Plug unit in Check circuit breakers or fuses Replace with proper part rated for the model Replace hi limit thermostat Test for continuity and replace if necessary Using the leg adjusters adjust the legs until level Shim cabinet until level Tighten the compression fitting Replace master valve Open valve Remove clean and replace valve Replace valve with new one 15 Service Manual for Electric Sealed Well Food Warmers MAINTENANCE STAINLESS STEEL CARE AND CLEANING Stainless steel contains 70 80 iron Iron will rust It also contains 12 3096 chromium Chromium forms an invisible passive film over the steel surface and acts as a shield against corrosion As long asthe protective film remains intact the metal will not corrode However if the film is broken or contaminated outside elements can begin to break down the steel and 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 or scrapers Avoid cleaning solutions that contain alkaline or chloride Use non alkaline based or non chloride cleaning solu
19. tions 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 For routine cleaning use warm soapy water For stubborn stains use a non abrasive cleanser For heavy grease use a degreaser For best results 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 16 CAUTION Never use an acid based cleanser Be sure to clean all food products from stainless surface Many food products contain acid which can deteriorate the finish Common 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 Neveruse ab
20. ts must be removed from their cabinets 2 Removethe screwsthathold the bottom cover in place 3 Slide the bottom cover toward the back of the unit and lift it out as depicted in Figure 2 In order to protect the wiring either the bottom cover must be supported to prevent damage orthe wiring mustbe tagged and disconnected with the cover set aside for reassembly 4 Tag and disconnect the element wiring Service Manual for Electric Sealed Well Food Warmers M Figure 11 Location of element pan lock nuts two each side 5 Remove the lock nuts that hold the element pantothe bottom ofthe sealed pan as depicted in Figure 11 6 Slide the element pan away from the drain support and out of the unit Remove the element support clips on the end of the pan 8 Remove the element from the center support bracket and lift it out of the element pan Element Element Figure 12 Element replacement 9 Replace the element Gently flex elementto fit it securely under the center support bracket Caution Use care when handling the new element Elements can break very easily 10 Replace the elementsupport clips that support the element loops on the edge of the pan 11 Place the element pan over the studs on the sealed pan 10 12 Replace the lock nuts to secure the element pan in place under the sealed pan 13 Reference the tags to connect element wiring 14 Reconnect the power wires and install the
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