SERVICE MANUAL - Catering Equipment and Repairs
Contents
1. MODEL GALLONS LITERS SHELF MODEL GALLONS LITERS SHELF 02 02 125 1 5 3 78 14 1200G 2 22 8 40 13 200NDNL 1 75 6 62 6 1200DW 2 3 8 71 14 200CT 1 75 6 62 6 1300G 2 32 8 78 13 2500 1 65 6 62 20 1600NDNL 2 1 7 95 6 250PNDT 2 1 7 95 6 19006 3 02 11 43 13 BW3 1 65 6 25 6 1900DW 3 06 11 58 14 BW4 1 7 6 44 6 2100DW 3 59 13 59 20 300NDNL 1 91 7 23 6 6000P 4 95 18 74 23 8 300CT 1 91 7 23 6 700DP 2 25 8 52 14 700NDNL 2 25 8 52 14 1500DP 3 01 11 39 14 700CT 2 25 8 52 14 742HW 2 45 9 27 14 950NDNL 2 16 8 18 20 744HW 3 11 36 28 3000C 2 24 8 48 14 1600HZ 25 9 46 WARRANTY Thermodyne Foodservice Products Inc warrants to the original purchaser for use of each new Thermodyne Conductive Cooking Holding Oven the following Any part which proves to be defective in materials or workmanship within the warranty period will subject to the terms of this warranty be repaired or replaced at Thermodyne Foodservice Inc s option Claims under this warranty must be presented to Thermodyne Foodservice Products Inc in writing promptly Thermodyne stainless steel cabinets are warranted for 5 years and all other original equipment parts such as heat transfer plates doors casters fluid system components and electrical components are warranted against defect for one year from the date of purchase This warranty applies only to Thermodyne Conductive Cooking Holding Ove2. Oxidizing material HAZARDOUS DECOMPOSITION PRODUCTS None HAZARDOUS POLYMERIZATION Will not occur ENVIROMENTAL AND DISPOSAL INFORMATION ACTION TO TAKE FOR SPILLS LEAKS Cover with absorbent material soak up and sweep into bag HEALTH HAZARD DATA EYE May cause slight transient eye irritation Corneal injury is unlikely SKIN CONTACT Essentially nonirritating to skin on prolonged contact SKIN ABSORPTION Asingle prolonged skin exposure is not likely to result in absorption of harmful amounts The LD50 for skin absorption in rabbits is 210 000 mg kg Repeated exposures may cause slight flaking tenderness and softening of skin INGESTION Single does oral toxicity is low The LD50 for female rats is about 20 3 g kg INHALATION Asingle prolonged hours inhalation exposure is not likely to cause adverse side effects Mists are notto be hazardous SYSTEMIC amp OTHER EFFECTS Repeated excessive ingestion may cause central nervous system effects No carcinogenic effects have been seen in long term animal studies Birth defects are unlikely Exposures having no adverse effects on the mother should have no effect on the fetus In animal studies has been shown not to interfere with reproduction Results of mutagenicity tests in vitro testtube and in animals have been negative FIRST AID EYES Irrigate immediately with water for at least 5 minutes SKIN wash off in flowing water or shower INGESTION In
3. PE 20 3STherimocouples 20 Heat Elements 22 MAINTENANCE PROCEDURES 24 Temperature Controller Set Up 24 Keypad Operaatio ios 24 Unlock the s 24 SEUD aaye 24 To Toggle Between F and 25 Changing the Heat Transfer A IIS aa kapaq nnne nnns nth nennen nnne neis 25 CT Door suus nig ioco cp teen eere 25 Stainless Steel CALS m eddi 26 TROUBLESHOOTING EET 27 WIRING SCHEMATIC 0 0 28 FLUID CAPACITIES STANDARD SHELF CONFIGURATION sess 30 WARRANT Y ERE 31 HEAT TRANSFER FLUID 9 8 31 ELECTRICAL LOCKOUT TAGOUT PROCEDURE vas Before performing any service that involves electrical connection or disconnection and or exposure to electrical components always follow the Electrical LOCKOUT TAGOUT Procedure Disconnect all circuits Failure to comply can cause prop
4. LOCKOUT TAGOUT PROCEDURE 5 COVERSANDPANEES uu uuu dua 6 G 6 OWS CAG cscs uuu EE 6 6 COMPONENT EQOGATO Ro E 7 Power Head 7 Delivery Manifold Comporients 21 0 8 Return Manifold Comporlents ER enu asas 9 COMPONENT REMOVAL AND n n a 10 Electrical iiit ct 10 Power Toggle 10 Fluid 11 ueri uiir aSrenie EEUU 11 12 CON LP M 13 POWER BOARD COMPONENTS Pav 13 50 State Relay Ra 13 120 Float BOI p E 14 SOONDNE TWELVE BUTTON TIMER unire e E iret x eq 15 PLUMBING COMPONENTS 1 16 B amp G PUMP ER 16 TORO OE EDU 17 18
5. adjustment alteration service or maintenance can cause property damage injury or death Electrical connections should be performed only by a certified professional A Electrical and grounding connections must comply with the applicable portions of the National Electric Code and or all local electric codes Failure to comply with this procedure can cause property damage injury or death VARNING Before connecting the unit to the electrical supply verify that the electrical and grounding connections comply with the applicable portions of the National Electric Code and or other local electrical codes Failure to comply with this procedure can cause property damage injury or death wane Before connecting the unit to the electrical supply verify that the electrical connection agrees with the specifications on the data plate Failure to comply with this procedure can cause property damage injury or death ene UL73 grounding instructions This appliance must be connected to a grounded metal permanent wiring system Or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the appliance Failure to comply with this procedure can cause property damage injury or death cae Appliances equipped with a flexible electric supply cord are provided with a three prong grounding plug It is imperative that this plug be connected into a p
6. an empty pan 5 Remove the Heater Tank Cap and the Reservoir Cap 6 Open the Drain Valve to drain the Heat Transfer Fluid 7 Discard the drained fluid refer to the Material Safety Data Sheet provided in this manual for Figure 22 Location of Thermocouple proper disposal of fluid 8 TheTBC 41 Controlleris very easy to remove 12 Install the new Thermocouple into the There are four springs and spacers apiece Heater Tank be careful not to damage holding the display and power boards They the Thermocouple lead while performing are different lengths the spacers used with this task the power board are 1 2 12 7mm long 13 Referring to the note made step 9 or the circuit springs used with the display board are 5 16 schematic connect the new Thermocouple 8mm long leads to the Controller terminals 14 Restore power to the unit 15 Close the fluid Drain Valve 16 Fill the Heater Tank and Reservoir Tank with fluid until the Low Fluid Light goes out 17 Ensure that are no leaks around the newly installed Thermocouple tighten as needed 18 Remove the unit from its power source 19 Reattached the Side Panel and Power Head Cover 1 2 12 7mm 20 Spacers 4 Restore power to the unit and verify the unit is operating correctly may be necessary to add additional fluid after the unit has operated Figure 21 Controller for several minutes 9 Note the location of and colors
7. in the Lockout Tagout Procedures section of this manual Remove the Power Head Lid following the instructions provided in the Panels and Covers section of this manual Tag and disconnect all of the component wires on the Power Board Remove the screws and plastic risers that secure the power board to the unit and lift the board and its components out of the unit Plastic Risers Figure 13 Power Board and Components Tag and disconnect the wires attached to the Twelve Button Timer Remove the screws securing the timer to the unit Figure 14 Twelve Button Timer with Power Board Removed 7 Replace the timer and reattach its wires 8 Reinstall the Power Board make sure each screw has its plastic riser installed 15 9 Referring to the tags or the wiring schematic reattach the Power Board component s wiring 10 Restore power to the unit and check the timer for proper operation 11 Remove the unit from its power source and reattach the Power Head Lid 12 Restore power to the unit and verify that the unit is operating correctly PLUMBING COMPONENTS A WARNING Before removing any sheet metal panels or servicing this equipment always perform the Electrical LOCKOUT TAGOUT Procedure Be sure all circuits are disconnected Failure to comply with this procedure can cause property damage injury or death N WARNING Certain components may be hot if the unit was in operation prio
8. of the Thermocouple wires on the Controller Before removing any sheet metal panels 10 Remove the wires for the Controller terminals or servicing this equipment always 11 Remove the Thermocouple from the Heater perform the Electrical LOCKOUT TAGOUT Tank Procedure Be sure all circuits are disconnected Failure to comply with this 21 procedure can cause property damage injury or death N WARNING Certain components may be hot if the unit was in operation prior to performing a procedure Allow the unit to cool before beginning work A WARNING Before servicing the plumbing system the heat transfer fluid must be drained from the system HEAT ELEMENTS The Heat Elements are located inside ofthe Heater Tank The Heater Tank must be removed to gain access to the Heat Elements Use this procedure to replace a Heat Element Before performing this procedure check each Heat Element with a continuity meter It is only necessary to replace the faulty element NOTICE In BW5SNDNL models the B amp G Pump and Heater Tank are located at the back of the unit Removal of the Back Panel is required when servicing the B amp G Pump or Heater Tank Components 1 Follow the LOCKOUT TAGOUT procedure using the procedures provided in the Lockout Tagout Procedures section of this manual 2 Remove the Power Head Lid following the instructions provided inthe Panels and Covers section of this manual 3 Removet
9. or death Under normal circumstances it is not necessary to remove the Back Panelto access components The exception to this is the BW3SNDNL model The Back Panel the BW3SNDNL provides access to the Heater Tank components and the Pump The Back Panel on the 950NDNL and 957NDNL may be lifted off to provide pass through access Follow the LOCKOUT TAGOUT procedure Remove the Philips screws securing the Back Panel Lift the Back Panel up and away from the unit UNITS WITH DOORS All CT models are supplied with doors The doors are provided with lift off hinges To remove the doors open the slightly and lift it straight up and off the hinge O DN COMPONENT LOCATOR POWER HEAD COMPONENTS Cooling Fan B amp G Pump Reservoir Fill Cap Reservoir Assembly Contactor Lighted Power Toggle Switch Add Fluid Light Temperature Controller Solid State Relay Figure 1 Power Head Components 10 11 12 13 14 15 16 17 120VAC Float Board Neutral Lug Heater Elements Snap Disc 16 PSI Pressure Cap Fluid Level Probes Thermocouple Heater Tank Assembly DELIVERY MANIFOLD COMPONENTS ooQGo T 4 6 5 Figure 2 Delivery Manifold Components 1 2 3 4 5 6 f Delivery Line Teflon Washer Shelf Plug Power Cord Delivery Manifold Assembly Short Teflon Hose
10. 10 LIQUID LEVEL CONTROL BK 10 LNC NS211 120 1 2 1 43 1 ovo 1 1 1 1 RESERVOIR 1 1 LEVEL PROBE 1 wu THERMOCOUPLE PROBE L LEVEL PROBES eee HEATER TANK REAR FAN 110 ro POWER BOARD TERMINALS L2 1 BK WH GN 120 VOLT SUPPLY PRIMARY POWER BOARD Standard 120 VAC Wiring 29 FAST TIMER FAST TIMER T2 5 BK18 TRANSFORMER 24V 80 TO 260 VOLTS IN OGDEN 9300 TC TC ON OFF ADD FLUID 711 18 T2 BK 18 110 V LIQUID LEVEL CONTROL 0 188 1 LNC NS211 120 SOLID STATE RELAY BK 181 0O 4 BK 10 3 32 VDC R 18 3 10 10 RELAY 55 RES V THERMOCOUPLE PROBE HEATER TANK REAR FAN 110V 120 208 240 VOLT CONNECTION GN Ny NOTE REMOVE JUMPER FOR ro POWER BOARD TERMINALS L2 L1 L2 Lr mire oue BK WH GN BK R W GN POWER BOARD 120 VOLT 208 240 VOLT SUPPLY SUPPLY 120 208 240 VAC Wiring FLUID CAPACITIES STANDARD SHELF CONFIGURATION
11. 4 Heater Tank Removal Carefully lift the Heater Tank out of the Power Head If the Thermocouple is still attached be careful not to place undue stress on the Thermocouple wires Remove Heat Elements Figure 25 Heater Tank with Heat Elements Removed Unscrew and remove the defective Heat Element Install the new Heat Element Using a NEW Flange Gasket reconnect the Heater Tank to the Return Manifold Reattach the Heater Tank to the Power Head chassis Tighten the Heat Element that was replaced Using a new Pump Union Gasket reconnect the pump to the tank Reconnect the Overflow Tube Referring to the tags or the wiring schematic reconnect all of the wires and leads If the Thermocouple was removed reinstall it 23 24 25 2D Restore power to the unit and fill the Heater Tank and Reservoir Tank with fresh Heat Transfer fluid until the Low Fluid Level light goes out Check for leaks at the Return Manifold Flange Pump Union Heat Element and the Thermocouple if it was removed Tighten as needed Remove the unit from its power source andreattach the left Side Panel and Power Head Cover Restore the unit to its power source and check the unit for proper operation may be necessary to add additional Heat Transfer Fluid after the unit has operated for several minutes 23 MAINTENANCE PROCEDURES TEMPERATURE CONTROLLER SET UP PROCEDURES Upper Display To display proc
12. 80 TO 260 t VOLTS IN 4 R 20 ADD FLUID a 110 V R 10 R 10 T t 24 4 J 10 LIQUID LEVEL BK 10 SULID STATE CONTROL RELAY LNC NS211 120 BK 18 4 d BK 10 MES BL 18 I 3 32 VDC 1 1 e PR 18 43 I R 18 3 10 O omo RESET BK 10 1 2 Bl RELAY 55 AMP RES w 18 GR 18 HEATERS 240V 3500W RESERVOIR TANK BK 10 T BK 18 L LEVEL PROBE BK 18 THERMOCOUPLE R 10 R 10 x c 7 I BK 18 An LEVEL l yaa PROBES L 9 REAR FAN HEATER TANK EE A 110 V TU PDWER BK WH GN 120 VOLT SUPPLY BOARD N NOTE REMOVE JUMPER FOR 120 208 240 VOLT CONNECTION TERMINALS BKR w GN 208 240 VOLT SUPPLY PRIMARY POWER BUARD Standard Wiring 28 FAST TIMER FAST TIMER T1 T2 80 TO 260 18 ON OFF VOLTS IN LE BK 18 OGDEN 9300 TRANSFORMER WO a 4 24V TC R 20 Di o 18 T2 BK 18 ADD FLUID R 10 H R10 BK
13. FLUID The Heat Transfer Fluid must be changed on an annual basis NEVER SUBSTITUTE THERMODYNE HEAT TRANSFER FLUID WITH WATER OR OTHER LIQUID 1 Follow the LOCKOUT TAGOUT procedure using the procedures provided in the Lockout Tagout Procedures section of this manual 2 Remove the Power Head Lid following the instructions provided in the Panels and Covers section of this manual 3 Removethe left side panelusing the procedures provided in the Panels and Covers section of this manual 4 Place the Drain Tube end into an empty pan Figure 27 Drain Tube amp Valve Location 5 Remove the Heater Tank and Reservoir caps Heater Tank Cap Reservoir Cap Figure 28 Heater Tank Cap amp Reservoir Cap 6 10 11 12 13 14 Open the Drain Valve to drain the Heat Transfer Fluid Discard the drained fluid refer to the Material Safety Data Sheet provided in this manual for proper disposal of fluid Closethe Drain Valve and stow the Drain Tube inside the cabinet Replace the Side Panel and the Power Head Lid Restore power to the unit and turn it on Fill the Heater Tank and replace the Pressure Cap Fillthe Reservoir until the Add Fluid Light goes out and replace the Reservoir Cap The Add Fluid Light may come on after a few minutes of operation Remove the Fill Cap Cover onthe Power Head Lid andthe Reservoir Cap
14. Shelf Elbow RETURN MANIFOLD COMPONENTS B occa e EUN 7 TR 9 O O p Che zy p Q O O O O 8 9pm O3 O ORK Che m 4 7 Figure 3 Return Manifold Components m om quc om xt Overflow Tube Shelf Plug Teflon Washer Drain Tube Drain Tube ON OFF Valve Return Manifold Long Teflon Hose Shelf Elbow COMPONENT REMOVAL AND REPLACEMENT d Power Toggle Switch ELECTRICAL COMPONENTS N WARNING Before removing any sheet metal panels or servicing this equipment always perform the Electrical LOCKOUT TAGOUT Procedure Be sure all circuits are disconnected Failure to comply with this procedure can cause property damage injury or death N WARNING Certain components may be hot if the unit was in operation prior to performing a procedure Allow the unit to cool before beginning work POWER TOGGLE SWITCH Follow the LOCKOUT TAGOUT procedure using the procedures provided in the Lockout Tagout Procedures section of this manual Remove the Power Head Lid following the instructions provided in the Panels and Covers section of this manual Tag and disconnect the wires connected to the Power Toggle Switch Squeeze the spring tabs that hold the switch in place and push the switch through the front of the unit NOTE If th
15. Tank and provides over temperature protection for the unit NOTICE In BW5SNDNL models the B amp G Pump and Heater Tank are located at the back of the unit Removal of the Back Panel is required when servicing the B amp G Pump or Heater Tank Components 1 Follow the LOCKOUT TAGOUT procedure using the procedures provided in the Lockout Tagout Procedures section of this manual 2 Remove the Power Head Lid following the instructions provided in the Panels and Covers section of this manual 3 Removethe left side panelusing the procedures provided in the Panels and Covers section of this manual 4 Locate the Drain Tube and place it into an empty pan 5 Removethe Heater Tank Cap andthe Reservoir Cap 6 Openthe Drain Valve to drain the Heat Transfer Fluid 7 Discard the drained fluid refer to the Material Safety Data Sheet provided in this manual for proper disposal of fluid 8 Tag and disconnect the Snap Disc wires Heater Tank Cap Reservoir Cap Snap Disk Figure 20 Location of Snap Disc 9 Remove the defective Snap Disc 10 Install the new Snap Disc 11 Referring to the tags or circuit schematic reconnect the wires to the Snap Disc 12 Restore power to the unit 13 Close the fluid Drain Valve 14 Fill the Heater Tank and Reservoir Tank with fluid until the Low Fluid Light goes out 15 Ensure that are no leaks around the newly installed probe tighten as needed 16 Remove the un
16. Thermodyne FOODSERVICE PRODUCTS INC SERVICE MANUAL gt gt 8 e e g L e MODELS 200 NDNL 300 NDNL 700 NDNL 957 NDNL 200 CT 300 CT 725 NDNL 1600 NDNL 250 PNDT 300 OC 950 NDNL BW3S NDNL For additional information on Thermodyne Foodservice Products Inc or to locate an authorized parts and service provider in your area visit our website at www tdyne com Please visit our website to Register your Thermodyne unit Registration ensures that you get up to date warranty and product information along with fast and convenient service hitp www tdyne com register aspx Thermodyne Foodservice Products Inc 4418 New Haven Avenue 1 800 526 9182 Fort Wayne IN 46803 www tdyne com 08 12 ELECTRICAL WARNINGS THIS MANUAL HAS BEEN PREPARED FOR PERSONNEL QUALIFIED TO INSTALL ELECTRICAL EQUIPMENT WHO SHOULD PERFORM THE INITIAL FIELD STARTUP AND ADJUSTMENTS OF THE EQUIPMENT COVERED BY THIS MANUAL READ THIS MANUAL THOROUGHLY BEFORE OPERATING INSTALLING OR PERFORMING MAINTENANCE ON THE EQUIPMENT Failure to follow all the instructions this manual can cause property damage injury or death PPP Improper installation
17. al Enter the Set Up Menu With the unit under power pressthe Scroll key for approximately 5 seconds until the upper display reads Orc O Outi O Out2 O Alm O MAN O AIT Press the Scroll key once The upper display will read LOCK Press the Down key until the lower display reads The controller is now unlocked Press the R buttonto return controller to the home position of reading Process Value amp Set Value Also referto pages 13 amp 14 in the TBC 41 Instruction Manual for complete LOCK parameter choices Test the controller by trying to change the set temperature up and down Set Up 1 Press the Up and Down key as needed to adjust the displayed set point temperature The OUT1 LED will be lit up solid during warm up normal operation Whenthe OUT1 LED is blinking the unit has reached the desired temperature NOTE This controller is not an indicator of fluid level in the Heater or Reservoir Tanks 24 Toggle Between F and Readout 1 Pressthe Scroll key 2 3times until the upper display reads unit 2 Press the Up or Down key to choose PV om a o IIll L ec Out2 Q oc MAN O SV Co W R CHANGING THE HEAT TRANSFER
18. ay be hot if the unit was in operation prior to performing a procedure Allow the unit to cool before beginning work COOLING FAN Follow the LOCKOUT TAGOUT procedure using the procedures provided in the Lockout Tagout Procedures section of this manual Remove the Power Head Lid following the instructions provided in the Panels and Covers section of this manual Unplug the leads from the fan Remove the four screws securing the fan to the Power Head Figure 8 Cooling Fan 5 Reverse this procedure to install the new Cooling Fan a WARNING Before removing any sheet metal panels or servicing this equipment always perform the Electrical LOCKOUT TAGOUT Procedure Be sure all circuits are disconnected Failure to comply with this procedure can cause property damage injury or death WARNING Certain components may be hot if the unit was in operation prior to performing a procedure Allow the unit to cool before beginning work 12 POWER CORD 1 Follow the LOCKOUT TAGOUT procedure using the procedures provided in the Lockout Tagout Procedures section of this manual 2 Remove the Power Head Lid following the instructions provided in the Panels and Covers section of this manual 3 Disconnectthe Power Cord from the Contactor and remove the ground screw securing the green ground wire to the unit s chaise 4 Refer to the unit s schematic connect the new power cord Restore power
19. ce CAUTION Never use steel wool which will leave behind particles that rust CAUTION Never use acid based or chloride containing cleaning solutions which will break down the protective film CAUTION Never rub in a circular motion CAUTION Never leave any food products or salt on the surface Many foods are acidic Salt contains chloride For routine cleaning use warm water mild soap or detergent and a sponge or soft cloth For heavy duty cleaning use warm water a degreaser and a plastic stainless steel or Scotch Brite pad Always rinse thoroughly Always rub gently in the direction of the steel grain Preserving amp Restoring Special stainless steel polishing cleaners can preserve and restore the protective film Preserve the life of stainless steel with a regular application of a high quality stainless steel polishing cleaner as a final step to daily cleaning If signs of breakdown appear restorethe stainless steel surface First thoroughly clean rinse and dry the surface Then on a daily basis apply a high quality stainless steel polish according to manufacturer s instructions Heat Tint Darkened areas called heat tint may appear on stainless steel exposed to excessive heat which causes the protective film to thicken It is unsightly but is not a sign of permanent damage To remove heat tint follow the routine cleaning procedure Stubborn heat tint will require heavy duty cleaning Tore
20. duce heattint limitthe exposure of equipment to excessive heat 26 TROUBLESHOOTING Problem Probable Cause Suggested Solution No Power Main Power Switch Off Place Power Switch in ON position Unit not plugged in Ensure unit is plugged into a live receptacle Circuit Breaker off or tripped Check and reset the Circuit Breaker Contactor Failure Replace the Contactor On Off switch Heater Tank fluid level low Remove unit from power source and fill Heater Tank to Pressure illuminated but controller will not illuminate Fluid Level Probe defective Cap neck with fresh Heat Transfer Fluid Determine which Fluid Level Probe is defective and replace it Unit continuously shuts down and requires fluid replenishment Add Fluid light illuminates every couple of days Fluid leak Remove the unit from power and remove the Power Head Lid and Side Covers Restore power and place the ON OFF switch in its ON position Observe the unit for leaks Repair leak and top of fluid levels Add Fluid light is illuminated but unit is operating normally Reservoir Tank low on fluid Top off Reservoir with fresh Heat Transfer Fluid Unit not reaching desired temperature Controller not set to 189 F Defective Controller Refer to Temperature Controller Set Up Procedures and set temperature to 189 F Refer to Temperature Controller replacement procedure and replace controller OUT light il
21. duce vomiting if large amounts are ingested consult medical INHALATION Remove to fresh air if effects occur Consult medical NOTE TO PHYSICIAN No specific antidote Supportive care Treatment based on judgment of the physician in response to reactions of the patient HANDLING PRECAUTIONS EXPOSURE GUIDELINE S Dow IHG is 10mg m3 for propylene glycol mist Dow IHG 440 ppm for propylene glycol vapors VENTILATION Good generalventilation sufficient RESPIRATORY PROTECTION No respiratory protection should be needed SKIN PROTECTION No precautions other than clean body covering should be needed EYE PROTECTION Use safety glasses ADDITIONAL INFORMATION REGULATORY REQUIREMENTS SARAHAZARDCATEGORY Thisproduct has been reviewed according to the EPA Hazard Categories promulgated under Section 311 and 312 of the Superfund Amendment and Reauthorization Act of 1986 SARA Title III and is considered under applicable definitions to meet the following categories A delayed hazard SPECIAL PRECAUTIONS TO BE TAKEN IN HANDLING AND STORAGE Exercise reasonable care and caution MSDS STATUS Revised Section 9 91
22. e switch being removed is damaged it may be easier to break the spring tabs off of the switch rather than attempting to squeeze the spring tabs If this method is used remember to remove the broken tabs from the inside of the Power Head Figure 4 Power Toggle Switch 10 Insert the new switch through the front of the unit ensuring the tabs have locked in place Referring to the tags or Circuit Schematic reconnect all of the wires Restore power to the unit and check the switch for proper operation Remove the units from power Replace the Power Head Lid Restore power to the unit and verify proper operation A WARNING Before removing any sheet metal panels or servicing this equipment always perform the Electrical LOCKOUT TAGOUT Procedure Be sure all circuits are disconnected Failure to comply with this procedure can cause property damage injury or death WARNING Certain components may be hot if the unit was in operation prior to performing a procedure Allow the unit to cool before beginning work 10 ADD FLUID LIGHT 1 Follow the LOCKOUT TAGOUT procedure using the procedures provided in the Lockout Tagout Procedures section of this manual 2 Remove the Power Head Lid following the instructions provided in the Panels and Covers section of this manual 3 Tag and disconnect the wires connected to the Add Fluid Light For easier access to the Add Fluid Light tag and di
23. erty damage injury or death A WARNING Certain components may be hot if the unit was in operation prior to performing a procedure Allow the unit to cool before beginning work A WARNING Before servicing the plumbing system the heat transfer fluid must be drained from the system TEFLON HOSES Under normal operating circumstances it should not be necessary to replace a hose Should a hose become damaged or begin leaking it must be replaced There are two sets of Teflon Hoses installed on each unit The short Teflon Hoses are located on the delivery side left side of the unit The long Teflon Hoses are located on the return side right side of the unit Both sets of hoses are replaced in the same manner 1 Follow the LOCKOUT TAGOUT procedure using the procedures provided in the Lockout Tagout Procedures section of this manual Remove the Power Head Lid following the instructions provided in the Panels and Covers section of this manual Remove the left side panel using the procedures provided in the Panels and Covers section of this manual Locate the Drain Tube and place it into an empty pan Remove the Heater Tank Cap and the Reservoir Cap Open the Drain Valve to drain the Heat Transfer Fluid Discard the drained fluid refer to the Material Safety Data Sheet provided in this manual for proper disposal of fluid 147 8 UsingaS3 40pen end wrench remove the hose from the Shelf Elbow side
24. erty damage injury or death The Electrical LOCKOUT TAGOUT Procedure is used to protect personnel working on an electrical appliance Before performing any maintenance or service that requires exposure to electrical components follow these steps Inelectrical box place appliance circuit breaker into OFF position Place a lock or other device on electrical box cover to prevent someone from placing circuit breaker ON Place a tag on electrical box cover to indicate that appliance has been disconnected for service and power should not be restored until tag is removed by maintenance personnel Disconnect appliance power cord from electrical outlet Place a tag on the cord to indicate that unit has been disconnected for service and power should not be restored until tag is removed by maintenance personnel COVERS AND PANELS TOP FILL COVER The TopFill Cover provides accessto the Reservoir Tank Cap without the requirement to remove the entire Power Head Lid Remove the cover to access the Reservoir Tank Cap when the Add Fluid Light is illuminated Place the Power Switch in its OFF position Remove the Philips screws securing the Top Fill Cover Remove the Top Fill Cover POWER HEAD LID N WARNING Before removing any sheet metal panels always perform the Electrical LOCKOUT TAGOUT Procedure Be sure all circuits are disconnected Failure to comply with this procedure can cause property damage injury
25. ess value menu symbol error code etc Process Output 1 Indicator O Output 2 l O Indicator Out2 PV nm Li LI L I LI LI To display set point value parameter value control output value etc O ooo o Alarm Al MAN I 1 Foal LLLI AT SV Manual Q Mode Indicator R CS 345 Auto Tuning Indicator Return Reset Key Scroll Key Down Key Up Key Figure 26 Controller Keypad Operation Scroll Key This key is usedto select a parameter to be viewed or adjusted Up Key This key is used to increase the value of the selected parameter Down Key wv This key is used to decrease the value of the parameter Return Reset Key R This key is used to 1 Return the display to indicate the Process Value PV and Set Value SV Reset a Latching Alarm once the alarm condition has cleared Discontinue Manual Control Auto Tuning and Calibration Modes Clearerrormessagesindicatingcommunication and auto tuning errors Re set the dwell timer function 6 Enter the manual control menu if the sensor has failed Unlock the Controller 1 Follow the LOCKOUT TAGOUT procedure using the procedures provided in the LOCKOUT TAGOUT Procedures of this manual Remove the Power Head Lid following the instructions provided in the Panels and Covers section of this manu
26. first 9 Using a 7 16 open end wrench remove the hose from the manifold T eo Teflon Tube Drain Tube Manifold oogooQooQ9ooQ Al Teflon Tube Figure 18 Delivery Side of Unit 9 Attached the replacement Teflon Hose to the manifold first than attach the other end to the Shelf Elbow using the appropriate wrenches 10 Close the Drain Valve 11 Restore power to the unit 12 Fill the Heater Tank with FRESH Heat Transfer Fluid and replace the Heater Tank Pressure Cap 13 Fill the Reservoir Tank until the Add Fluid Light goes out and replace the Reservoir Tank Cap 14 Ensure there are no leaks around the fittings of the new hose 15 Remove the unit from its power source 16 Reattach all covers and panels 17 Restore the unit s power check it for proper operation It may be necessary to add additional fluid after the unit has operated for several minutes 18 After the unit has operated for several minutes remove the Side Panel where the hose was replaced and ensure that it is not leaking Tighten as necessary 19 Reattach the removed Side Panel N WARNING Before removing any sheet metal panels or servicing this equipment always perform the Electrical LOCKOUT TAGOUT Procedure Be sure all circuits are disconnected Failure to comply with this procedure can cause property dama
27. ge injury or death A WARNING Certain components may be hot if the unit was in operation prior to performing a procedure Allow the unit to cool before beginning work A WARNING Before servicing the plumbing system the heat transfer fluid must be drained from the system FLUID LEVEL PROBES There are two Fluid Level Probes One is installed in the Heater Tank the other is installed in the Reservoir Tank Before changing either of the 18 probes check the fluid levels in the Heater Tank and the Reservoir Tank Also check the electrical connection to the probes The probes should test as open with a continuity test when the tanks are filled with fluid With an empty tank the probe should test as closed during a continuity test NOTICE In BW5SNDNL models the B amp G Pump and Heater Tank are located at the back of the unit Removal ofthe Back Panelis required when servicing the B amp G Pump or Heater Tank Components 1 Follow the LOCKOUT TAGOUT procedure using the procedures provided in the Lockout Tagout Procedures section of this manual 2 Remove the Power Head Lid following the instructions provided in the Panels and Covers section of this manual 3 Removethe left side panelusing the procedures provided in the Panels and Covers section of this manual 4 Locate the Drain Tube and place it into an empty pan 5 Remove the Heater Tank Cap and the Reservoir Cap 6 Open the Drain Valve to drai
28. he Display Pushbutton Board These two boards are connected by a multi conductor ribbon cable Main Board Display Pushbutton Figure 6 Temperature Controller 1 Follow the LOCKOUT TAGOUT procedure using the procedures provided in the Lockout Tagout Procedures section of this manual 2 Remove the Power Head Lid following the instructions provided in the Panels and Covers section of this manual 11 The TBC 41 Controller is very easy to remove There are four screws and spacers apiece holding the display and power boards They are different lengths the spacers used with the power board are 1 2 12 7mm long the spacers used with the display board are 5 16 8mm long 1 2 12 7mm Spacers 4 Figure 7 Temperature Controller Removal 4 Restore the power and check the controller for proper operation Remove the unit from its power source and reattach the Power Head Lid Restore power to the unit and ensure it is operating correctly NOTICE The new Temperature Controller may require set up procedures Refer to the Temperature Controller Set Up Procedures section of this manual for set up procedures N WARNING Before removing any sheet metal panels or servicing this equipment always perform the Electrical LOCKOUT TAGOUT Procedure Be sure all circuits are disconnected Failure to comply with this procedure can cause property damage injury or death WARNING Certain components m
29. he left side panelusing the procedures provided in the Panels and Covers section of this manual 4 Locate the Drain Tube and place it into an empty pan 5 Remove the Heater Tank Cap and the Reservoir Cap 6 Open the Drain Valve to drain the Heat Transfer Fluid 7 Discard the drained fluid refer to the Material Safety Data Sheet provided in this manual for proper disposal of fluid 8 Tag and disconnect the Snap Disc Leads Fluid Level Probe wire Heat Element leads and the tank ground wire NOTE It may not be necessary to remove the Thermocouple to change the Heat Elements If Thermocouple needs to be removed refer to the Thermocouple replacement procedure in this manual 9 Before removing the Heater Tank loosen the Heat Elements with an appropriately sized wrench 10 Remove the nuts and bolts securing the Heater Tank to the Return Manifold Loosen Heat Elements Heater Tank Heater Tank Connection Manifold Connection Figure 23 Heater Tank to Return Manifold Connection 11 Disconnectthe Overflow Tube atthe Pressure Cap on the Heater Tank 12 Completely loosen the Pump Union on the tank side of the pump 13 Remove the nuts securing the Heater Tank to the unit s chassis Heater Tank Mounting 14 15 16 17 18 19 20 21 22 Loosen Pump Union Figure 2
30. isposal of fluid 8 Tag and disconnect the B amp G pump wires 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Using the 1 1 16 wrench remove the Delivery Line Using the 1 3 8 wrench unscrew the unions on both sides of the pump Using the 7 16 wrench remove the U clamp securing the pump to the Pump Bracket and remove the pump Place the new pump into position Loosely connect the U clamp Ensure NEW gaskets are in place at both unions tighten the unions using the 1 3 8 wrench Tighten the 7 16 nuts on the U clamp Reconnect the Delivery Line Referring to the tags or circuit schematic reconnect the pump wires Close the Drain Valve Restore power to the unit Fill the Heater Tank with FRESH Heat Transfer Fluid and replace the Heater Tank Pressure Cap Fill the Reservoir Tank until the Add Fluid Light goes out and replace the Reservoir Tank Cap Ensure there are no leaks at the pump unions or Delivery Line fitting Remove the unit from its power source Reattach all covers and panels Restore the unit s power check it for proper operation It may be necessary to add additional fluid after the unit has operated for several minutes A WARNING Before removing any sheet metal panels or servicing this equipment always perform the Electrical LOCKOUT TAGOUT Procedure Be sure all circuits are disconnected Failure to comply with this procedure can cause prop
31. it from its power source 17 Reattached the Side Panel and Power Head Cover 18 Restore power to the unit and verify the unit is operating correctly It may be necessary to add additional fluid after the unit has operated for several minutes N WARNING Before removing any sheet metal panels or servicing this equipment always perform the Electrical LOCKOUT TAGOUT Procedure Be sure all circuits are disconnected Failure to comply with this procedure can cause property damage injury or death WARNING Certain components may be hot if the unit was in operation prior to performing a procedure Allow the unit to cool before beginning work AN WARNING Before servicing the plumbing system the heat transfer fluid must be drained from the system THERMOCOUPLE The Thermocouple is located on the Heater Tank NOTICE In BW5SNDNL models the B amp G Pump and Heater Tank are located at the back of the unit Removal of the Back Panel is required when servicing the B amp G Pump or Heater Tank Components 1 Follow the LOCKOUT TAGOUT procedure using the procedures provided inthe Lockout Thermocouple Tagout Procedures section of this manual 2 Remove the Power Head Lid following the instructions provided in the Panels and Covers section of this manual 3 Removetheleftside panelusingthe procedures provided in the Panels and Covers section of this manual 4 Locate the Drain Tube and place it into
32. lity information should be retained for future reference For assistance please call Toll Free 800 526 9182 Local 260 428 2535 1 HEAT TRANSFER FLUID MSDS Dow Chemical U S A Midland MI 48674 Emergency Phone 517 636 4400 Product Code 23545 Product Name PROPYLENE GLYCOL HEAT TRANSFER FLUID Effective Date 03 02 88 Date Printed 06 02 88 MSDS 000130 INGREDIENTS Propylene glycol 000057 55 6 9596 Dipotassium phosphate CAS 007758 11 4 lt 5 Deionized water CAS 007732 18 5 lt 5 This documentis prepared pursuanttothe OSHA Hazard Communication Standard 29CFR 1910 1200 In addition other substances not Hazardous per this OSHA Standard may be listed Where proprietary ingredient shows the identity may be made available as provided in this standard PHYSICAL DATA BOILING POINT 370F 188C VAP PRESS 0 22 mmHg 20C 68F VAP DENSITY 2 62 SOL IN WATER Complete SP Gravity 1 050 60 60 16 APPEARANCE Colorless ODOR Odorless liquid FIRE AND EXPLOSION HAZARD DATA FLASH POINT 215F 102C METHOD USED COC FLAMMABLE LIMITS LFL 2 6 100C UFL 12 5 130C EXTINGUISHING MEDIA Water fog alcohol foam dry chemical FIRE AND EXPLOSION HAZARDS None FIRE FIGHTING EQUIPMENT None REACTIVITY DATA STABILITY CONDITIONS TO AVOID Stable over normal Operating temperature range of 30F to 250F INCOMPATIBILITY SPECIFIC MATERIALS TO AVOID
33. luminated but unit not heating up Defective Solid State Relay Defective or tripped Snap Disc Refer to Solid State Relay replacement procedure and replace relay Note If relay LED is illuminated check Snap Disc Reset Snap Disc If unit fails to warm up replace Snap Disc Some shelves heat while others remain cold Shelf or Delivery Return Hose is plugged Replace defective shelf or defective hose Note Delivery and Return hoses are different lengths Extreme Electrical Load clicking noise or controller turning on and off Fluid Level in Heater Tank low Faulty Contactor Remove unit from power and top off Heater Tank with fresh Heat Transfer Fluid Replace the Contactor Loud Squealing Noise Controller reads SBER on top screen Defective Pressure Cap or Pressure Cap Gasket Defective Pump Defective Thermocouple Replace the 16 PSI Pressure Cap Replace the defective pump referring to the pump replacement procedures Refer to Thermocouple replacement procedure and replace the Thermocouple LoT WIRING SCHEMATIC FAST TIMER OPTION FAST TIMER N UFF 4 M TEe TEL
34. n the Heat Transfer Fluid 7 Discard the drained fluid refer to the Material Safety Data Sheet provided in this manual for proper disposal of fluid Figure 19 Fluid Sensor Probes 8 Disconnect the Fluid Sensor Probe lead 9 Remove the defective probe 10 Install the new probe 11 Reconnect the probe lead 12 Restore power to the unit 13 Close the fluid Drain Valve 14 Fill the Heater Tank and Reservoir Tank with fluid until the Low Fluid Light goes out 15 Ensure that are no leaks around the newly installed probe tighten as needed 16 Remove the unit from its power source 17 Reattached the Side Panel and Power Head Cover 18 Restore power to the unit and verify the unit is operating correctly may be necessary to add additional fluid after the unit has operated for several minutes A WARNING Before removing any sheet metal panels or servicing this equipment always perform the Electrical LOCKOUT TAGOUT Procedure Be sure all circuits are disconnected Failure to comply with this procedure can cause property damage injury or death N WARNING Certain components may be hot if the unit was in operation prior to performing a procedure Allow the unit to cool before beginning work WARNING Before servicing the plumbing system the heat transfer fluid must be drained from the system 19 SNAP DISC The Snap Disc is located on the Heater
35. ns in the Continental United States This warranty shall not apply if the oven or any part is subjected to accident casualty alteration misuse abuse neglect faulty installation or if the date of manufacture is altered or removed The obligation of Thermodyne Foodservice Products Inc is limited specifically to the aforementioned No additional guarantees or warranty expressed or implied to include without limitation warranties of Fitness or Merchantability with respect to Thermodyne Conduction Ovens and Thermodyne Foodservice Products Inc regarding other liability with respect thereto including without limitation liability for incidental special or consequential damages RESPONSIBILITIES OF PURCHASER It is the responsibility of the purchaser to 1 Arrange on site electrical services in accordance with Thermodyne specifications 2 Receive shipment of Thermodyne conduction oven to include unloading uncrating inspecting for damage in shipment and installation of the oven in its proper location in accordance with installation instructions 3 Arrange that the electric services are connected properly by a qualified technician All such connections must be in accordance with applicable code requirements and Thermodyne installation procedures Please note the specific details on the Warranty and make certain that service connections are made to the proper utility Services This warranty and purchasers responsibi
36. r to performing a procedure Allow the unit to cool before beginning work N WARNING Before servicing the plumbing system the heat transfer fluid must be drained from the system B amp G PUMP NOTICE In BW5SNDNL models the B amp G Pump and Heater Tank are located at the back of the unit Removal of the Back Panel is required when servicing the B amp G Pump or Heater Tank Components Additional tools required for this procedure e 1 1 16 Wrench e 1 3 8 Wrench 7 16 Wrench 1 Follow the LOCKOUT TAGOUT procedure using the procedures provided in the Lockout Tagout Procedures section of this manual 2 Remove the Power Head Lid following the instructions provided in the Panels and Covers section of this manual 3 Remove the left side panel using the procedures provided in the Panels and Covers section of this manual 4 Locate the Drain Tube and place it into an empty pan Figure 15 Drain Tube amp Drain Valve Location 5 Remove the Heater Tank Cap and the Reservoir Cap Gaskets Heater Tank Cap B amp G Pump Reservoir Unions Delivery Hose Fitting Pump Bracket Figure 16 B amp G Pump Removal 16 Open the Drain Valve to drain the Transfer Fluid Discard the drained fluid refer to the Heat Transfer Fluid Material Safety Data Sheet provided in this manual for proper d
37. roperly grounded three prong receptacle Failure to comply with this procedure can cause property damage injury or death If the receptacle is the proper grounding type contact an electrician Do not remove the grounding prong from the plug Failure to comply with this procedure can cause property damage injury or death 7 waste Before performing any service that involves electrical connection or disconnection and or exposure to electrical components always perform the Electrical LOCKOUT TAGOUT Procedure Disconnect all circuits Failure to comply with this procedure can cause property damage injury or death iene Before removing any sheet metal panels always perform the Electrical LOCKOUT TAGOUT Procedure Be sure all circuits are disconnected Failure to comply with this procedure can cause property damage injury or death Eae Do not operate this equipment without properly placing and securing all covers and access panels Failure to comply with this procedure can cause property damage injury or death Do not use or store gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance Failure to comply can cause property damage injury or death In the event of a power failure do not attempt to operate this appliance Failure to comply can cause property damage injury or death TABLE OF CONTENTS iEzenmle m ec 2 ELECTRICAL
38. sconnect the Power Toggle Switch wires 4 Squeeze the spring tabs that hold the Add Fluid Light in place and push it through the front of the unit Power Toggle Switch Add Fluid Light Figure 5 Add Fluid Light 5 Insertthe new Add Fluid Light through the front of the unit ensuring the tabs have locked in place 6 Referring to the tags or Circuit Schematic reconnect the wires 7 Restore power to the unit and check the Add Fluid Light for proper operation NOTE TheAdd Fluid Light will not illuminate if the Heat Transfer Fluid level is sufficient Drain fluid as necessary in order to test for proper light operation Refer to the Changing the Heat Transfer Fluid section of this manual for procedures on draining and adding Heat Transfer Fluid 8 Remove the units from power 9 Replace the Power Head Lid 10 Restore power to the unit and verify proper operation A WARNING Before removing any sheet metal panels or servicing this equipment always perform the Electrical LOCKOUT TAGOUT Procedure Be sure all circuits are disconnected Failure to comply with this procedure can cause property damage injury or death N WARNING Certain components may be hot if the unit was in operation prior to performing a procedure Allow the unit to cool before beginning work TEMPERATURE CONTROLLER The Temperature Controller consists of two parts the Controller Main Board wire harness terminals and t
39. tion of this manual 2 Remove the Power Head Lid following the instructions provided in the Panels and Covers section of this manual 3 Tag and disconnect the wires mounted to the Solid State Relay 4 Remove the Solid State Relay by removing the four screws securing it to the Power Board It may be necessary to loosen screws securing the Power Board to gain access to the screws at the front of the relay Mounting Power Board Mounting Screws Plastic Riser Figure 10 Solid State Relay Install the new Solid State Relay Reattachthe screws securing the Power Board to the unit 7 Referring to the tags or to the wiring schematic reconnect the wires to the new relay 8 Restore power to the unit and verify operation 9 Remove the unit from its power source and reattach the Power Head Lid 10 Restore power to the unit and check it for proper operation N WARNING Before removing any sheet metal panels or servicing this equipment always perform the Electrical LOCKOUT TAGOUT Procedure Be sure all circuits are disconnected Failure to comply with this procedure can cause property damage injury or death N WARNING Certain components may be hot if the unit was in operation prior to performing a procedure Allow the unit to cool before beginning work 120VAC Float Board 1 Follow the LOCKOUT TAGOUT procedure using the procedures provided in the Lockout Tagout Procedures sec
40. tion of this manual 2 Remove the Power Head Lid following the instructions provided in the Panels and Covers section of this manual 3 Tag and disconnect the wires attached to the 120VAC Float Board 4 Removethe screws and plastic risers securing the float board to the Power Board and lift the float board out of the unit Float Board Mounting Screws Plastic Riser Figure 11 120VAC Float Board NOTE It is NOT necessary to loosen the Power Board screws to gain access to the float board 5 Installthenewfloatboard making sure a plastic riser is attached it each screw 6 Referring to the tags or the wiring schematic reconnect the wires to the float board 7 Restore power to the unit and check it for proper operation 8 Remove the units from its power source and reattach the Power Head Lid 9 Restore power to the units and verify its operation 14 N WARNING Before removing any sheet metal panels or servicing this equipment always perform the Electrical LOCKOUT TAGOUT Procedure Be sure all circuits are disconnected Failure to comply with this procedure can cause property damage injury or death N WARNING Certain components may be hot if the unit was in operation prior to performing a procedure Allow the unit to cool before beginning work 300NDNL TWELVE BUTTON TIMER Figure 12 300NDNL Twelve Button Timer Follow the LOCKOUT TAGOUT procedure using the procedures provided
41. to the unit Verify unit is working properly Remove the unit from its power supply Reattach the Power Head Lid Restore power to the unit and ensure unit is operating correctly o POWER BOARD COMPONENTS The Power Board Components include the Solid State Relay Contactor 120VAC Float Board and the Neutral Lug Under normal circumstances it should not be necessary to replace either the Contactor or Neutral Lug Neutral Lug Contactor 120VAC Float Board Solid State Relay Figure 9 Power Board Component Locator NOTICE The Power Board is mounted on plastic risers that allow for air flow on the underside of the board It is not necessary to remove the board when replacing one of its components however it may be necessary to loosen the screws that secure the Power Board to the unit Loosen the screws but do not remove them as they will hold the plastic risers in place WARNING Before removing any sheet metal panels or servicing this equipment always perform the Electrical LOCKOUT TAGOUT Procedure Be sure all circuits are disconnected Failure to comply with this procedure can cause property damage injury or death N WARNING Certain components may be hot if the unit was in operation prior to performing a procedure Allow the unit to cool before beginning work Solid State Relay 1 Follow the LOCKOUT TAGOUT procedure using the procedures provided in the Lockout Tagout Procedures sec
42. top off the Reservoir until the Add Fluid Light goes out Reattach the Fill Cap Cover to the Power Head Lid CT DOOR ADJUSTMENT Follow the LOCKOUT TAGOUT procedure using the procedures provided in the Lockout Tagout Procedures section of this manual Allow the unit to cool Remove the Side Panels following the procedures provided in the Covers and Panels section of this manual 25 4 Lift the door s up and off of the unit 5 Loosen the hinges on the unit Screws amp Figure 29 Location of Hinge Screws Reattach the door s to the loosened hinges Close the door s and align them in the closed position Tighten the hinge screws Make sure the doors open and close properly 10 Attach the Side Panels 11 Restore the unit to its power source STAINLESS STEEL CARE Cleaning Stainless steel contains 70 80 iron which will rust if not properly maintained It also contains 12 3096 chromium which forms an invisible passive protective film that shields against corrosion If the film remains intact the stainless steel will remain intact However if the film is damaged the stainless steel can break down and rust To prevent stainless steel breakdown follow these steps CAUTION Never use any metal tools Scrapers files wire brushes or scouring pads except for stainless steel scouring pads will mar the surfa
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