HENNY PENNY HHC-997 (01) PDF MANUAL


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PDF Content Summary: Henny Penny Humidified Holding Cabinets Model HHC-990 Model HHC-992 Model HHC-993 Model HHC-996 Model HHC-997 Model HHC-998 TECHNICAL MANUAL Model HHC-990/992/993/996/997/998 LIMITED WARRANTY FOR HENNY PENNY APPLIANCES Subject to the following conditions, Henny Penny Corporation makes the following limited warranties to the original purchaser only for Henny Penny appliances and replacement parts: NEW EQUIPMENT: Any part of a new appliance, except lamps and fuses, which proves to be defective in material or workmanship within two (2) years from date of original installation, will be repaired or replaced without charge F.O.B. factory, Eaton, Ohio, or F.O.B. authorized distributor. To validate this warranty, the registration card for the appliance must be mailed to Henny Penny within ten (10) days after installation. REPLACEMENT PARTS: Any appliance replacement part, except lamps and fuses, which proves to be defective in material or workmanship within ninety (90) days from date of original installation will be repaired or replaced without charge F.O.B. factory, Eaton, Ohio, or F.O.B. authorized distributor. The warranty for new equipment and replacement parts covers only the repair or replacement of the defective part and does not include any labor charges for the removal and installation of any parts, travel or other expenses incidental to the repair or replacement of a part. EXTENDED FRYPOT WARRANTY: Henny Penny will replace any frypot that fails due to manufacturing or workmanship issues for a period of up to seven (7) years from date of manufacture. This warranty shall not cover any frypot that fails due to any misuse or abuse, such as heating of the frypot without shortening. 0 TO 3 YEARS: During this time, any frypot that fails due to manufacturing or workmanship issues will be replaced at no charge for parts, labor, or freight. Henny Penny will either install a new frypot at no cost or provide a new or reconditioned replacement fryer at no cost. 3 TO 7 YEARS: During this time, any frypot that fails due to manufacturing or workmanship issues will be replaced at no charge for the frypot only. Any freight charges and labor costs to install the new frypot as well as the cost of any other parts replaced, such as insulation, thermal sensors, high limits, fittings, and hardware, will be the responsibility of the owner. Any claim must be presented to either Henny Penny or the distributor from whom the appliance was purchased. No allowance will be granted for repairs made by anyone else without Henny Penny’s written consent. If damage occurs during shipping, notify the sender at once so that a claim may be filed. THE ABOVE LIMITED WARRANTY SETS FORTH THE SOLE REMEDY AGAINST HENNY PENNY FOR ANY BREACH OF WARRANTY OR OTHER TERM. BUYER AGREES THAT NO OTHER REMEDY (INCLUDING CLAIMS FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES) SHALL BE AVAILABLE. The above limited warranty does not apply (a) to damage resulting from accident, alteration, misuse, or abuse; (b) if the equipment’s serial number is removed or defaced; or (c) for lamps and fuses. THE ABOVE LIMITED WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUD ING MERCHANTABILITY AND FITNESS, AND ALL OTHER WARRANTIES ARE EXCLUDED. HENNY PENNY NEITHER ASSUMES NOR AUTHORIZES ANY PERSON TO ASSUME FOR IT ANY OTHER OBLIGATION OR LIABILITY. FM06-005 Revised 07-30-07 Model HHC-990/992/993/996/997/998 TABLE OF CONTENTS Section Page Section 1. TROUBLESHOOTING 1-1. Introduction ................................................................................................................. 1-1 1-1. Safety .......................................................................................................................... 1-1 1-3. Troubleshooting .......................................................................................................... 1-1 1-4. Error Codes and Warnings .......................................................................................... 1-5 1-5. Info Mode .................................................................................................................... 1-8 Section 2. LEVEL 2 PROGRAMMING 2-1. Introduction ................................................................................................................. 2-1 2-2. Tech Mode................................................................................................................... 2-1 2-3. Stats Mode................................................................................................................... 2-5 2-4. Data Logging and Manufacturing Mode ..................................................................... 2-8 Section 3. MAINTENANCE 3-1. Introduction ................................................................................................................. 3-1 3-2. Maintenance Hints ...................................................................................................... 3-1 3-3. Humidity Sensor Calibration and Replacement .......................................................... 3-1 3-4. Fuse and Fuse Holder Assembly ................................................................................. 3-4 3-5. Power Switch Replacement ........................................................................................ 3-5 3-6. Air Temperature Probe Replacement .......................................................................... 3-6 3-7. Transformer Replacement ........................................................................................... 3-8 3-8. Food Probe Receptacle Replacement .......................................................................... 3-8 3-9. Relay Replacement ..................................................................................................... 3-9 3-10. Module Top Removal .................................................................................................. 3-10 3-11. Cooling Fan Replacement ........................................................................................... 3-11 3-12. High Limit - Air Heater Replacement ......................................................................... 3-11 3-13. Blower Motor Replacement ........................................................................................ 3-12 3-14. Air Heater Replacement .............................................................................................. 3-13 3-15. Speaker Replacement .................................................................................................. 3-13 3-16. Complete Panel or PC Board Replacement ................................................................ 3-14 3-17. Float Switch Replacement .......................................................................................... 3-15 3-18. High Limit - Water Heater Replacement..................................................................... 3-16 3-19. Water Heater Replacement.......................................................................................... 3-17 3-20. Drain Valve Replacement............................................................................................ 3-18 3-21. Door Gasket Replacement .......................................................................................... 3-19 3-22. Vent Motor Replacement ............................................................................................ 3-19 3-23. Vent Motor Microswitch Replacement ....................................................................... 3-20 Wiring Diagrams ......................................................................................................... 3-21 Section 4. PARTS INFORMATION 4-1. Introduction ................................................................................................................. 4-1 4-2. Genuine Parts .............................................................................................................. 4-1 4-3. When Ordering Parts................................................................................................... 4-1 4-4. Prices........................................................................................................................... 4-1 4-5. Delivery ....................................................................................................................... 4-1 4-6. Warranty ...................................................................................................................... 4-1 4-7. Recommended Spare Parts for Distributors ............................................................... 4-1 Parts List ..................................................................................................................... 4-2 i 206 Model HHC-990/992/993/996/997/998

1-1. INTRODUCTION SECTION 1. TROUBLESHOOTING This section provides troubleshooting information in the form of an easy to read table. If a problem occurs during the first operation of a cabinet, recheck the installation per the Installation Section of the Operator’s Manual Before troubleshooting, always recheck the operation proce dures in the Operator’s Manual.

1-2. SAFETY Where information is of particular importance or is safety related, the words NOTICE, CAUTION, or WARNING are used. Their usage is described below. SAFETY ALERT SYMBOL is used with DANGER, WARNING, or CAUTION which indicates a personal injury type hazard. NOTICE is used to highlight especially important information. CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. CAUTION used with the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. 1-3. TROUBLESHOOTING To isolate a malfunction, proceed as follows: 1. Clearly define the problem or symptom and when it occurs. 2. Locate the problem in the troubleshooting table. 3. Review all possible causes. Then, one at a time work through the list of corrections until problem is solved. If maintenance procedures are not followed correctly, injuries and/or property damage could result. 903 1-1 Model HHC-990/992/993/996/997/998 1-3. TROUBLESHOOTING (continued) Problem Cause Correction OPERATION A. Product not • Doors left open • Keep doors closed except holding temperature to load and serve product • Product held too long • Hold product only for recom- mended times • Control temperature set too low • Increase air temperature setpoint (SP-3) in Special Program Mode • Bad air heater • Check heaters and replace if bad See Tech Mode items 10 and 18 • Blower not working • Check blower and replace if bad See Tech Mode item 20 • Bad air heater, or blower relays • Replace relay See Tech Mode items 10 and 18 • Bad high limit • Check high limit and replace if bad • Low or improper voltage • Compare receptacle voltage to data plate voltage • Door gasket torn or worn • Replace bad door gaskets • Air probe faulty, open (“E-6A”), • Ohm out the probe and replace or shorted (“E-6B”) if necessary B. Cabinet steaming • Humidity setpoint too high • Decrease humidity setpoint or product soggy (SP-4) in Special Program Mode • Water heater probe faulty, open • Ohm out the probe and replace (“E-12A”), or closed (“E-12B”) if necessary • Bad humidity sensor (“E17”) • Replace humidity sensor • Relay stuck closed • Replace relay • Vent stuck closed (“E-80”) • Bad vent motor - replace • Bad vent motor relay - replace- See Tech Mode item 20 • Check alignment and condition of mechanical vent parts 1-2 903

1-3. TROUBLESHOOTING (continued) Model HHC-990/992/993/996/997/998

Problem Cause Correction OPERATION (Continued) C. Product dry • Bad float switch (“E-18”) • Replace float switch • Bad water heater high limit • Replace high limit • Bad water heater • Check heater and replace if bad; see Tech Mode item 20 • Humidity setpoint too low • Increase humidity setpoint (SP-4) in Special Program Mode • No water in pan • Pour water in water pan • Vent stuck open (“E-80”) • Bad vent motor - replace; see Tech Mode item 20 • Bad vent motor relay - replace • Check alignment and condition of mechanical vent parts HEATING SYSTEM A. Unit not heating • Bad control board • Replace control board • Bad high limit • Check high limit; replace if bad • Bad air heater or blower relays • Replace relay • Bad air heater • Check heaters and replace if bad; see Tech Mode item 20 • Faulty wiring • Check for loose connections or broken wires • Blown Fuse • Change 15 amp fuse B. Unit not reaching set • Blower not working. • Check Blower and replace if bad; temperature see Tech Mode item 20 • Bad air heater • Check heaters and replace if bad; see Tech Mode item 20 • Bad air heater, or blower relays • Replace relay • Doors left open • Keep doors closed except to load and serve product • Door gasket torn or worn • Replace bad door gaskets 903 1-3

1-3. TROUBLESHOOTING (continued) Model HHC-990/992/993/996/997/998

Problem Cause Correction HEATING SYSTEM (Continued) C. Unit Overheating • Blower not working • Check blower and replace if bad (“E-5”) See Tech Mode item 20 • Bad control board • Replace control board • Relay stuck closed • Replace relay 1-4 903 Model HHC-990/992/993/996/997/998 1-4. ERROR CODES AND The display shows the following error codes and warnings when a WARNINGS fault is detected, along with an alarm sound. Both the heat and humidity systems shut down, except when specified otherwise. Display Cause Panel Board Correction

“E-4 CPU TOO HOT” • Control board too hot; unit overheating or louvers clogged “E-5 AIR TEMP TOO HOT” • Faulty relay, PC board, or air probe “E-54A CPU TEMP SENSOR • Faulty PC board OPEN” “E-54B CPU TEMP SENSOR • Faulty PC board SHORTED” “E-6A AIR TEMP SENSOR • Faulty air probe FAILED OPEN” • Turn switch to OFF position, then back to ON; if display still shows “E-4”, the PC board is getting too hot; clean louvers and check cooling fan; if cooling fan is not working, have it replaced; once panel cools down, the controls should return to normal; if “E-4” persists, have the PC board replaced • Turn switch to OFF position, then back to ON; if display shows “E-5”, the heating circuits and temperature probe should be checked; once the unit cools down, the controls should return to normal; if “E-5” persists, have the PC board replaced • Turn switch to OFF position, then back to ON; if display shows “E-54A”, the control should be re-initialized (see Pro gramming Section); if the error code persists, have PC board replaced • Turn switch to OFF position, then back to ON; if display shows “E-54B”, the control should be re-initialized (see Pro gramming Section); if the error code persists, have PC board replaced • Turn switch to OFF position, then back to ON; if the display shows “E-6”, the temperature probe should be checked; once the temperature probe is repaired, or replaced, the controls should return to normal; if “E-6” persists, have the PC board replaced

804 1-5

1-4. ERROR CODES AND WARNINGS (Continued) Model HHC-990/992/993/996/997/998

Display Cause Panel Board Correction

“E-6B AIR TEMP SENSOR • Faulty air temperature FAILED SHORTED” probe “E-12A WATER HEATER • Faulty water SENSOR FAILED heater probe OPEN” “E-12B WATER HEATER • Faulty water SENSOR FAILED heater probe CLOSED” “E-17 HUMIDITY SENSOR • Faulty humidity sensor FAILED” “E-18 NO WATER, FLOAT • Float switch stuck or SWITCH FAILED” faulty; faulty relay (stuck on);water pan needs cleaned; loose or faulty water heater sensor; acorn nuts on water heater cover loose, or water heater insulation missing or damaged • Turn switch to OFF position, then back to ON; if the display shows “E-6”, the temperature probe should be checked; once the temperature probe is repaired, or replaced, the controls should return to normal; if “E-6”persists, have PC board replaced • Turn switch to OFF position, then back to ON; if the display shows “E-12A”, the water heater should be checked and repaired or replaced (the water heater probe is built into the water heater); the controls should return to normal; if “E-12A” persists, have PC board replaced • Turn switch to OFF position, then back to ON; if the display shows “E-12B”, the water heater should be checked and repaired or replaced (the water heater probe is built into the water heater); the controls should return to normal; if “E-12B” persists, have PC board replaced • Turn switch to OFF position, then back to ON; if the display shows “E-17”, the humidity sensor should be checked; once the humidity sensor is repaired, or replaced, the controls should return to normal; if “E-17” persists, have PC board replaced • Turn switch to OFF position, then back to ON; if the display shows “E-18”, check and clean float switch; clean water pan; have relay and water heater sensor checked and replace if necessary; tighten acorn nuts on water heater cover; make sure 2 complete pieces of insulation are under the water heater cover; if “E-18” persists, have PC board replaced

A humidity error only shuts down the humidity system. If a humidity error occurs, and you want to use the cabinet without humidity, turn the humidity off by following the directions for SP-4, Humidity Setpoint, in Special Programming Section of this manual. Once the setpoint is off, the alarm stops, but the error code shows in display. (Includes “E-12A”, “E-12B”, “E-17” and “E-18”). 1-6 804 Model HHC-990/992/993/996/997/998 1-4. ERROR CODES AND WARNINGS (Continued) Display Cause Panel Board Correction

“E-41 SYSTEM DATA LOST” • Memory scrambled “E-46 DATA SAVE FAILED” • Memory scrambled “E-80 VENT STUCK OR • Vent on rear of module BAD SWITCH” stuck or faulty vent activation switch “PLEASE DE-LIME • Water pan needs WATER PAN” cleaned “WATER LEVEL LOW, PLEASE” • Water pan low on water or empty • Turn switch to OFF position, then back to ON; if the display shows “E-41”, the control should be re-initialized (see Pro gramming Section); if “E-41”persists, have PC board replaced • Turn switch to OFF position, then back to ON; if the display shows “E-46”, the control should be re-initialized (see Pro gramming Section); if “E-46”persists, have PC board replaced • Check vent on rear of module for obstruc tions, or have vent activation switch replaced • Follow the weekly cleaning procedures; this warning will not shut down the heat or humidity; if “PLEASE DE-LIME WATER PAN” persists, have PC board replaced • Fill water pan, in bottom of unit, to the maximum water fill mark; this warning won’t shut down the heat or humidity

804 1-7 Model HHC-990/992/993/996/997/998 1-5. INFO MODE This mode records historic information on the holding cabinet and operator performance, which could help in troubleshooting a problem. This mode records historic information on the unit and operator performance. Press and at the same time and “*INFO MODE*” shows on display. Press or to access the steps and press to view the statistics within each step. Information Mode is intended for technical use, but the opera tor can view the following information: 1. Error Log - last 10 errors and time they occurred 2. Power Up Log - time of last 10 power-ups 3. Outputs/Inputs - shows the state of unit’s inputs and outputs a. OUT V_F_W_A (vent motor, fan, water heater, air heater, relay order from left to right) b. AMPS V_F_W_A_ c. NC/GD V_F_W_A_ (no connect/ground detection on outputs to relays) d. All outputs and inputs V_F_W_A_ P_ (power switch input) E_(exhaust vent switch input) F_ (float switch input) 4. Vent - open or closed 5. CPU temperature 6. Cabinet air temperature 7. Water heater temperature 8. Food probe temperature 9. Humidity counts value 10. Humidity value 11. Analog inputs 1-8 906

1-5. INFO MODE (Continued) Model HHC-990/992/993/996/997/998 1. E-LOG (error code log) Press and “1A. (date & time) *NOW*” shows in display. This is the present date and time. Press and if a error was recorded, “1B. (date, time, and error code information)” shows in display. This is the latest error code that the controls recorded. Press and the next latest error code information can be seen. Up to 10 error codes (1B to 1K) can be stored in the E LOG section. Press to continue to P-LOG. 2. P-LOG (power-up log) Press and “2A. (date & time) *NOW*” shows in display. This is the present date and time. Press and the latest power-up is shown, “2B. (date, time,) PWR-UP”. Press and the next latest power-up date is shown. Up to 10 power-ups (2B to 2K) can be stored in the P-LOG section. Press to continue onto the Outputs/Inputs. 3. OUTPUTS/INPUTS This mode displays the status of components and inputs. If the input or output signal is detected, an identifying letter is displayed (see below). If the signal is not detected, “_” is displayed. Press to view the following: a. “V_F_W_A_” shows in the display. If the output is on, “*” shows beside the output letter. Ex: “V*”. If the control senses a problem with the output, “*” flashes. b. “AMPS V_F_W_A_” shows in the display. A checkmark (“√” ) beside the letter indicates normal amps . A flashing “X” beside the letter means a problem exists. c. “NC/GD V_F_W_A_” shows in the display. This monitors a possible problem with the relays on the output PC board. A checkmark (“√” ) beside the letter indicates means everything on the output PC board is good. A flashing “X” beside the letter means a problem exists.

903 1-9 Model HHC-990/992/993/996/997/998 1-5. INFO MODE (Continued) 3. OUTPUTS/INPUTS (Continued) d. V_F_W_A_ P_E_F_ shows in the display. If the output or input signal is detected, “*” shows beside the letter. Ex: “V*”. If the control senses a problem with the output, “*” flashes. Press to continue onto VENT. 4. VENT This indicates whether the vent is open or closed. Press to continue onto CPU TMP. 5. CPU TMP This step shows the present PC board temperature. Press to continue onto the Cabinet Air TMP. 6. CABINET AIR TMP This step shows the present air temperature inside the cabinet. Press to continue onto the Water Heater TMP. 7. WATER HEATER TMP This step shows the present water heater temperature. Press to continue to Food TMP. 8. FOOD TMP This step shows the present food probe temperature, if used. Press to continue onto Humidity Counts Value. 9. HUMIDITY COUNTS VALUE Factory use only! Press to continue onto the Humidity Value. 10. HUMIDITY VALUE This step shows the present humidity level inside the cabinet. Press to continue onto the Analog Inputs. 1-10 903 Model HHC-990/992/993/996/997/998 1-5. INFO MODE (Continued) 11. ANALOG INPUTS (Continued) This step displays the present status of any channel of the controller’s a to d converter. This feature may be useful to a technician troubleshooting a problem with the controller. The displayed value can be toggled between volts and bits by pressing . If the displayed value has a decimal point, it is voltage (0 to 5 VDC). If no decimal point is shown, the value is a-to-d bits (0 - 4095). 903 1-11

2-1. INTRODUCTION2-2. TECH MODE Model HHC-990/992/993/996/997/998 SECTION 2. LEVEL 2 PROGRAMMING The Tech Mode and Stats Mode in the Level 2 Programming, have information that could help in troubleshooting a problem with the unit. Press and hold until “L-2 LEVEL 2”, followed by, “CLOCK SET”, shows in display. Press 3 times and “TECH”, followed by, “ENTER CODE” shows in display. Enter code, to access the following items: T-1 Software T-2 Cabinet version T-3 Push button test T-4 All on display test T-5 Segments test T-6 Digits test T-7 Decimal points test T-8 LED test T-9 Air temperature - circuit calibration T-10 Air temperature - user calibration/offset/highest value T-11 Water heater temperature - circuit calibration T-12 Water heater temperature - user calibration/offset/highest value T-13 Food temperature - circuit calibration T-14 Food temperature - user calibration/offset/highest value T-15 Humidity - circuit calibration T-16 Humidity sensor – calibration/offset; specific value sent with each humidity sensor T-17 Humidity- user calibration/offset/highest value T-18 CPU° - control temperature - highest value T-19 View ADC channel T-20 Outputs/Inputs; on outputs steps use the following hidden buttons [1-4] to toggle on the outputs; [1] - vent motor [2] - circulation fan, [3] - water heater, [4] - air heater T-21 Total init – initialization of programming areas and statistics moves you forward through the above selections and moves you backwards through the selections.

903 2-1

2-2. TECH MODE (Continued) Model HHC-990/992/993/996/997/998 T-1: Software This section shows “PN/ID/SRL” Press . Henny Penny EPROM part number is displayed. Press . Customer ID (i.e. Wendy’s) is displayed Press . Software revision is displayed. T-2: Cabinet Version This section shows the model number, e.i. HHC-993. T3: Push Button Test Press any button on the control and a digital display feedback confirms the button is working. T4: All On Display Test Press any of the product buttons and every LED on the 16 digit display lights. T5: Segments Test Repeatedly pressing any product button lights one segments in every one of the 16 digit displays. T6: Digits Test Repeatedly pressing any product button lights all segments in one of the 16 digital displays. (Scrolls though all 16.) T7: Decimal Point Test Repeatedly pressing any product button lights a decimal point (DP) in one of the 16 digital displays. (Scrolls though all 16.) T8: LED Test Repeatedly pressing any product button lights individual LEDs. (Scrolls though all LEDs.) T9: Air Temperature - Circuit Calibration Factory use.

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2-2. TECH MODE (Continued) Model HHC-990/992/993/996/997/998 T10: Air Temperature - Calibration/Offset/Highest This is a user calibration to make sure the display shows the actual air temperature. Press and hold and use to set the display to match the actual temperature. (+/-15o F) Press and hold to change the amount of the offset.(+/-15o F) Press and hold to view the highest air temperature recorded. Press to reset highest temperature. T11: Water Heater Temperature - Circuit Calibration Factory use. T12: Water Heater Temperature - Calibration/Offset/ Highest This is a user calibration to make sure the display shows the actual water heater temperature. Press and hold and use to set the display to match the actual temperature. (+/-15o F) Press and hold to change the amount of the offset.(+/-15o F) Press and hold to view the highest air temperature recorded. Press to reset highest temperature. T13: Food Probe Temperature - Circuit Calibration Factory use. T14: Food Probe Temperature - Calibration/Offset/Highest This is a user calibration to make sure the display shows the actual food temperature, when using the food probe. Press and hold and use to set the display to match the actual temperature. (+/-15o F) Press and hold to change the amount of the offset.(+/-15o F) Press and hold to view the highest air temperature recorded. Press to reset highest temperature.

903 2-3 Model HHC-990/992/993/996/997/998 2-2. TECH MODE (Continued) T15: Humidity - Circuit Calibration See Section 3-3 on Humidity Sensor Calibration and Replacement. T16: Humidity Sensor - Calibration/Offset This is a specific value that is sent with the humidity sensor, when necessary. Otherwise, this value should be 0. T17: Humidity - Calibration/Offset/Highest This is a user calibration to make sure the display shows the actual humidity inside the cabinet. Press and hold and use to set the display to match the actual humidity. (0 to 100%) Press and hold to change the amount of the offset.(-0 to -99) Press and hold to view the highest humidity recorded. Press to reset highest humidity. T18: CPUo - Control Temperature - Highest Value This shows the highest temperature the control board was exposed to. T19: View ADC Channel Factory use. T20: Outputs/Inputs The following components can be tested: toggles the vent motor off and on. toggles the cooling fan off and on. toggles the water heater off and on. toggles the air heaters off and on. T21: Total Initialization This completely resets any accumulated information and changed settings in the controls. Contact Henny Penny before completing this step. 2-4 705 Model HHC-990/992/993/996/997/998 2-3. STATS MODE Press and hold until “L-2 LEVEL 2”, followed by, “CLOCK SET”, shows in display. Press 4 times and “STATS”, followed by, “ENTER CODE” shows in display. Enter code, to access the following items: ST-1 Power live hours ST-2 Power ‘on’ hours ST-3 Power-ups count ST-4 Errors count ST-5 Air heat ‘on’ hours ST-6 Water heater ‘on’ hours ST-7 Circulation fan ‘on’ hours ST-8 Water solenoid on hours (no usage for 99X units) ST-9 Solenoid cycle count (no usage for 99X units) ST-10 Longest solenoid on time; max.=5 minutes (no usage for 99X units) ST-11 Vent motor ST-12 Highest air temperature ST-13 Highest water heater temperature ST-14 Highest food temperature ST-15 Highest humidity value ST-16 Highest CPU temperature ST-17 Water heater (too hot) cycle count ST-18 Sys ram – fade count ST-19 Hold ram – fade count ST-20 Stat ram – fade count ST-21 Ram data error count ST-22 Data total loss count ST-23 User init’s count ST-24 Auto init’s count ST-25 Error log ST-26 Power-up log ST-27 Heat-up log ST-28 Reset all stats moves you forward through the above selections and moves you backwards through the selections. 903 2-5 Model HHC-990/992/993/996/997/998 2-3. STATS MODE (Continued) ST-1: Power Live Hours This section shows the number of hours the control has been on. ST-2: Power On Hours This section shows the number of hours the control has been on. ST-3: Power Ups Count This section shows the number of times the control has been turned on. ST-4: Errors Count This section shows the total number of all errors (displayed on control) that have occurred with the unit. ST-5: Air Heat On Hours This section shows the number of hours the air heaters have been on. ST-6: Water Heater On Hours This section shows the number of hours the water heater has been on. ST-7: Circulation Fan On Hours This section shows the number of hours the cooling fan has been on. ST-8: Water Solenoid On Hours Shows the number of hours the solenoid has been on. ST-9: Solenoid Cycle Count Shows the number of times the solenoid has been turned on. ST-10: Longest Solenoid ‘On’ time. Maximum 5 minutes. Shows the longest the solenoid has been on at any one time, to a maximum of 5 minutes. ST-11: Vent Motor On Hours This section shows the number of hours the vent motor has been on. ST-12: Highest Air Temperature This section shows highest air temperature sensed by the temperature probe. 2-6 903 Model HHC-990/992/993/996/997/998 2-3. STATS MODE (Continued) ST-13: Highest Water Heater Temperature This section shows the highest water heater temperature, sensed by the water heater temperature sensor. ST-14: Highest Food Temperature This section shows the highest food temperature sensed by the food probe. ST-15: Highest Humidity Value This section shows the highest humidity value sensed by the humidity sensor. ST-16: Highest CPU Temperature This section shows the highest control board temperature sensed by the control. ST-17: Water heater (too hot) cycle count Shows the number of times the water heater has gotten too hot ST-18: System Ram - Fade Count This section shows the number of times the system memory has been lost during power up. Ex: oF or oC, or speaker volume. ST-19: Hold Ram - Fade Count This section shows the number of times the hold memory has been lost during a power up. May be lost at a power up, after a power loss, during a holding cycle. ST-20: Stat Ram - Fade Count This section shows the number of times the stats memory has been lost during power up. The information in the Stats Mode is updated every two hours, and this count lets you know that the updates were lost. ST-21: Ram Data Error Count This section shows the number of times the data was lost while operating, not during power up. (Should be a low number.) ST-22: Data Total Loss Count This section shows the number of times the data stored in the Eprom has been lost. Should see an “E-41” error code when this occurs. ST-23: User Init’s Count This section shows the number of times the operator has initialized the controls. 903 2-7

2-3. STATS MODE (Continued) 2-4. DATA LOGGING AND MANUFACTURING MODE Model HHC-990/992/993/996/997/998 ST-24: Auto Init’s Count This section shows the number of times the controls have initialized itself. ST-25: Error Log This section records the last 10 errors and the time they oc curred. Press to view the log. ST-26: Power Up Log This section records the last 10 power ups and when they occurred. Press to view the log. ST-27: Heat Up Log This section records the last 10 heat ups between 250o F (121o C) to 300o F (149o C), when they occurred, and how long (seconds) it took. Press to view the log. ST-28: Resets All Stats This section allows the user to reset all data stored in the Stats Mode. Press and hold for 3 seconds. The Data Logging and Manufacturing Mode are mainly for Henny Penny use only. For more information on these modes, contact the Service Department at 1-800-417- 8405, or 1-937- 456-8405.

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SECTION 3. MAINTENANCE Model HHC-990/992/993/996/997/998 3-1. INTRODUCTION 3-2. MAINTENANCE HINTS 3-3. HUMIDITY SENSOR CALIBRATION AND REPLACEMENT Figure 3-1Figure 3-2 This section provides procedures for the checkout and re placement of the various parts used within the merchandiser. Before replacing any parts, refer to the Troubleshooting Sec tion. It will aid you in determining the cause of the malfunc tion. 1. You may want to use a multimeter to check the electric components. 2. When the manual refers to the circuit being closed, the multimeter should read zero unless otherwise noted. 3. When the manual refers to the circuit being open, the multi meter reads infinity. The humidity sensor relays the cabinet humidity to the controls. If it becomes faulty, “E-17”, then “HUMIDITY SENSOR FAILED” shows on the display. Replace sensor as follows: To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. Replacement: 1. Open top, operator side door of full-size units, or operator door of 1/2 size units. 2. Using a Phillip’s head screwdriver, remove the front screw and loosen the 2 side screws securing the sensor cover. Slide cover towards you and over loosened screws. Figure 3-1 3. Using a Phillip’s head screwdriver, remove the 4 screws securing the sensor to the box. Figure 3-2.

903 3-1 Model HHC-990/992/993/996/997/998 3-3. HUMIDITY SENSOR CALIBRATION AND REPLACEMENT (Continued) 4. Pull the sensor assembly from the box and disconnect the wires. Figure 3-3. 5. Connect wires of new sensor and attach the sensor to the box. Follow the calibration instructions below before re attaching the sensor cover. 6. Once the calibration is complete, slide the cover over the Phillip’s head screws and tighten. Unit is now ready for

Figure 3-3 Figure 3-4 use. Calibration: Calibrate the humidity sensor after a sensor or control replace ment. A calibration board is supplied with each control kit and humidity sensor kit, but can also be ordered separately with part number, 14391. 1. If not already done, open the cabinet door, and remove the humidity sensor cover at top of unit. (See step 2, page 3-1.) 2. While holding the white tube, unscrew the silver cap from the humidity sensor. 3. Remove the two pronged sensor by grasping the edges. Figure 3-4. Use caution not to touch the flat edge, as it will throw the reading off. 4. Push and hold until “Level 2” appears in display. 5. Press to step through the menu until “TECH’ is displayed.

3-2 903

3-3. HUMIDITY SENSOR CALIBRATION AND REPLACEMENT (Continued) Model HHC-990/992/993/996/997/998 6. Using the timer buttons, (Figure 3-5), enter code of 11221122.

Figure 3-5 7. Press to step through menu to step 15. 8. Insert the two prongs of the calibration board marked 20% into the humidity sensor. Figure 3-6. 9. Press and hold , then press . Release both buttons. 20% should then show in display. 10. Reverse calibration board and insert the two prongs marked 80% into humidity sensor. 11. Push and hold then press . Release both buttons. 80% should then show in display.

Figure 3-6 12. Push to step 16. 13. Find the offset number on the mounting plate of the humidity

sensor.

When changing the control board on units with serial number IV178JB and below, no offset will be found. Leave offset at 0. 14. Push and hold , then press to enter the offset number. 15. Press and hold to exit Tech Mode. 16. Reinstall two pronged sensor into humidity sensor. 17. Reinstall silver cap and sensor cover, and unit is now ready for use. 705 3-3

3-4. FUSE AND FUSE HOLDER ASSEMBLY Figure 3-7 Checking Fuse Holder(s) Figure 3-8 Figure 3-9 Model HHC-990/992/993/996/997/998 If the unit (non-CE) is completely inoperative, but power exists at the wall receptacle, check the 15 amp fuse(s) and fuse holder(s) as follows: To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. Checking Fuse(s) 1. Unscrew the fuse holder cap by turning it counterclock wise. (Located under the power cord.) Figure 3-7. 2. Pull the fuse from the cap and check for continuity by placing the leads of a multimeter or continuity light on opposite ends of the fuse. The fuse should show closed or read no resistance. If fuse is defective, replace it with a new one. Be sure replacement fuse is identical to the one being replaced. (208 or 240 volt units have 2 fuses and both should be checked.) If fuses show good, the fuse holders may be bad. Check the fuse holders as follows: To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. 1. Remove the screws securing the rear access panel and pull panel down. 2. Remove the wires from the fuse holder, and check for continuity by placing the leads of a multimeter or continu ity light on terminals of the fuse holder. The fuse holder should show closed or read no resistance. Figure 3-8. 3. If fuse holder shows it’s defective, remove the screws securing it to the panel and replace it with a new one. Figure 3-9. 4. Reinstall the rear panel and make sure the fuse holder has a 15 amp fuse in it. 5. Restore power to the cabinet and it’s now ready for use.

3-4 903 Model HHC-990/992/993/996/997/998 3-5. POWER SWITCH REPLACEMENT To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. 1. Using a Phillip’s head screwdriver, remove the four screws securing the front panel.

Figure 3-10 Figure 3-11 Figure 3-12 2. Pull panel down, pull connectors from the back of it, and remove panel from unit. 3. Using 5/16” socket, remove the 4 nuts securing the control cover and remove cover. Figure 3-10. 4. Pull wires from switch and check across the 2 terminals for continuity. Figure 3-11. With switch in ON position, the circuit should be closed. In the OFF position, the circuit should be open. If the switch is defective, continue with step 5. 5. Pinch the tabs on the rear of the switch and pull the switch through the front of the panel. Figure 3-12. 6. Replace with new switch in reverse order and unit is now ready for use.

903 3-5 Model HHC-990/992/993/996/997/998 3-6. AIR TEMPERATURE PROBE REPLACEMENT To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. 1. Using a Phillip’s head screwdriver, remove the four screws securing the front panel.

Figure 3-13 Figure 3-14 Figure 3-15 2. Pull panel down, pull connectors from the back of it, and remove panel from unit. 3. Unplug the wires to the probe. Figure 3-13. 4. Using a multimeter, or ohmmeter, check across the probe terminals for the correct ohms using the RTD Resistance Chart on the following page. If the probe proves faulty, continue onto step 5. 5. Using a 3/4” wrench, loosen probe strain relief and pull the probe from the unit. Figure 3-14. 6. Slide new probe through the strain relief, extending the probe about 1” (25.4 mm) into the cabinet area. Figure 3-15. 7. Plug probe wires to the unit, tighten the strain relief, and replace front panel. Unit is now ready for use.

3-6 903 Model HHC-990/992/993/996/997/998 RTD Resistance Chart e c n a t s i s e R . p m e T . p m e T e c n a t s i s e R . p m e T . p m e T e c n a t s i s e R . p m e T . p m e T e c n a t s i s e R . p m e T . p m e T e c n a t s i s e R . p m e T . p m e T s m h O CF s m h O CF s m h O CF s m h O CF s m h O CF 7 5. 67 3 1 8 7. 7 9 802 7 4. 38 2 1 3 3. 3 7 461 7 6. 98 1 1 9 8. 8 4 7 7 021 8 1. 59 0 1 4 4. 4 2 67 0 0. 00 0 1 0 0. 0 23 8 6. 87 3 1 3 3. 8 9 902 9 5. 58 2 1 9 8. 3 7 561 1 8. 19 1 1 4 4. 9 4 121 3 3. 79 0 1 0 0. 52 7 1. 20 0 1 6 5. 0 33 9 7. 08 3 1 9 8. 8 9 012 1 7. 78 2 1 4 4. 4 7 661 5 9. 39 1 1 0 0. 0 5 221 9 4. 99 0 1 6 5. 5 2 87 4 3. 40 0 1 1 1. 1 43 9 8. 28 3 1 4 4. 9 9 11 2 4 8. 98 2 1 0 0. 5 7 761 9 0. 69 1 1 6 5. 0 5 321 4 6. 10 1 1 1 1. 6 2 97 1 5. 60 0 1 7 6. 1 53 0 0. 58 3 1 0 0. 0 0 1 212 6 9. 19 2 1 6 5. 5 7 861 3 2. 89 1 1 1 1. 1 5 421 0 8. 30 1 1 7 6. 6 2 08 8 6. 80 0 1 2 2. 2 63 1 1. 78 3 1 6 5. 0 0 1 312 8 0. 49 2 1 1 1. 6 7 961 6 3. 00 2 1 7 6. 1 5 521 5 9. 50 1 1 2 2. 7 2 18 5 8. 01 0 1 8 7. 2 73 1 2. 98 3 1 1 1. 1 0 1 412 0 2. 69 2 1 7 6. 6 7 071 0 5. 20 2 1 2 2. 2 5 621 0 1. 80 1 1 8 7. 7 2 28 2 0. 31 0 1 3 3. 3 83 2 3. 19 3 1 7 6. 1 0 1 512 2 3. 89 2 1 2 2. 7 7 171 4 6. 40 2 1 8 7. 2 5 721 6 2. 0 1 1 1 3 3. 8 2 38 8 1. 51 0 1 9 8. 3 93 2 4. 39 3 1 2 2. 2 0 1 612 5 4. 00 3 1 8 7. 7 7 271 8 7. 60 2 1 3 3. 3 5 821 1 4. 2 1 1 1 9 8. 8 2 48 5 3. 71 0 1 4 4. 4 04 3 5. 59 3 1 8 7. 2 0 1 712 7 5. 20 3 1 3 3. 8 7 371 1 9. 80 2 1 9 8. 3 5 921 6 5. 4 1 1 1 4 4. 9 2 58 2 5. 91 0 1 0 0. 5 14 3 6. 79 3 1 3 3. 3 0 1 812 9 6. 40 3 1 9 8. 8 7 471 5 0. 11 2 1 4 4. 4 5 031 2 7. 6 1 1 1 0 0. 0 3 68 9 6. 12 0 1 6 5. 5 24 4 7. 99 3 1 9 8. 3 0 1 912 1 8. 60 3 1 4 4. 9 7 571 8 1. 31 2 1 0 0. 5 5 131 7 8. 8 1 1 1 6 5. 0 3 78 6 8. 32 0 1 1 1. 6 34 4 8. 10 4 1 4 4. 4 0 1 022 3 9. 80 3 1 0 0. 0 8 671 2 3. 51 2 1 6 5. 5 5 231 2 0. 12 1 1 1 1. 1 3 88 2 0. 62 0 1 7 6. 6 44 5 9. 30 4 1 0 0. 5 0 1 122 5 0. 11 3 1 6 5. 0 8 771 5 4. 71 2 1 1 1. 6 5 331 7 1. 32 1 1 7 6. 1 3 98 9 1. 82 0 1 2 2. 7 54 5 0. 60 4 1 6 5. 5 0 1 222 7 1. 31 3 1 1 1. 1 8 871 9 5. 91 2 1 7 6. 6 5 431 2 3. 52 1 1 2 2. 2 3 09 6 3. 03 0 1 8 7. 7 64 5 1. 80 4 1 1 1. 6 0 1 322 8 2. 51 3 1 7 6. 1 8 971 2 7. 12 2 1 2 2. 7 5 531 7 4. 72 1 1 8 7. 2 3 19 2 5. 23 0 1 3 3. 8 74 5 2. 01 4 1 7 6. 6 0 1 422 0 4. 71 3 1 2 2. 2 8 081 6 8. 32 2 1 8 7. 7 5 631 2 6. 92 1 1 3 3. 3 3 29 9 6. 43 0 1 9 8. 8 84 6 3. 21 4 1 2 2. 7 0 1 522 2 5. 91 3 1 8 7. 2 8 181 9 9. 52 2 1 3 3. 8 5 731 7 7. 13 1 1 9 8. 3 3 39 5 8. 63 0 1 4 4. 9 94 6 4. 41 4 1 8 7. 7 0 1 622 4 6. 12 3 1 3 3. 3 8 281 2 1. 82 2 1 9 8. 8 5 831 2 9. 33 1 1 4 4. 4 3 49 2 0. 93 0 1 0 0. 0 1 05 6 5. 61 4 1 3 3. 8 0 1 722 6 7. 32 3 1 9 8. 3 8 381 6 2. 03 2 1 4 4. 9 5 931 7 0. 63 1 1 0 0. 5 3 59 8 1. 14 0 1 6 5. 0 1 15 6 6. 81 4 1 9 8. 8 0 1 822 7 8. 52 3 1 4 4. 4 8 481 9 3. 23 2 1 0 0. 0 6 041 2 2. 83 1 1 6 5. 5 3 69 5 3. 34 0 1 1 1. 1 1 25 6 7. 02 4 1 4 4. 9 0 1 922 9 9. 72 3 1 0 0. 5 8 581 2 5. 43 2 1 6 5. 0 6 141 6 3. 04 1 1 1 1. 6 3 79 1 5. 54 0 1 7 6. 1 1 35 6 8. 22 4 1 0 0. 0 1 1 032 0 1. 03 3 1 6 5. 5 8 681 5 6. 63 2 1 1 1. 1 6 241 1 5. 24 1 1 7 6. 6 3 89 7 6. 74 0 1 2 2. 2 1 45 6 9. 42 4 1 6 5. 0 1 1 132 2 2. 23 3 1 1 1. 6 8 781 9 7. 83 2 1 7 6. 1 6 341 6 6. 44 1 1 2 2. 7 3 99 4 8. 94 0 1 8 7. 2 1 55 6 0. 72 4 1 1 1. 1 1 1 232 4 3. 43 3 1 7 6. 6 8 881 2 9. 04 2 1 2 2. 2 6 441 1 8. 64 1 1 8 7. 7 3 001 0 0. 25 0 1 3 3. 3 1 65 6 1. 92 4 1 7 6. 1 1 1 332 5 4. 63 3 1 2 2. 7 8 981 5 0. 34 2 1 8 7. 2 6 541 5 9. 84 1 1 3 3. 8 3 101 6 1. 45 0 1 9 8. 3 1 75 6 2. 13 4 1 2 2. 2 1 1 432 7 5. 83 3 1 8 7. 7 8 091 8 1. 54 2 1 3 3. 3 6 641 0 1. 15 1 1 9 8. 8 3 201 2 3. 65 0 1 4 4. 4 1 85 6 3. 33 4 1 8 7. 2 1 1 532 8 6. 04 3 1 3 3. 8 8 191 1 3. 74 2 1 9 8. 3 6 741 4 2. 35 1 1 4 4. 9 3 301 9 4. 85 0 1 0 0. 5 1 95 6 4. 53 4 1 3 3. 3 1 1 632 9 7. 24 3 1 9 8. 8 8 291 4 4. 94 2 1 4 4. 4 6 841 9 3. 55 1 1 0 0. 0 4 401 5 6. 06 0 1 6 5. 5 1 06 5 5. 73 4 1 9 8. 3 1 1 732 1 9. 44 3 1 4 4. 9 8 391 7 5. 15 2 1 0 0. 5 6 941 3 5. 75 1 1 6 5. 0 4 501 1 8. 26 0 1 1 1. 6 1 16 5 6. 93 4 1 4 4. 4 1 1 832 2 0. 74 3 1 0 0. 0 9 491 0 7. 35 2 1 6 5. 5 6 051 8 6. 95 1 1 1 1. 1 4 601 7 9. 46 0 1 7 6. 6 1 26 5 7. 14 4 1 0 0. 5 1 1 932 3 1. 94 3 1 6 5. 0 9 591 3 8. 55 2 1 1 1. 6 6 151 2 8. 16 1 1 7 6. 1 4 701 3 1. 76 0 1 2 2. 7 1 36 5 8. 34 4 1 6 5. 5 1 1 042 5 2. 15 3 1 1 1. 1 9 691 5 9. 75 2 1 7 6. 6 6 251 7 9. 36 1 1 2 2. 2 4 801 9 2. 96 0 1 8 7. 7 1 46 4 9. 54 4 1 1 1. 6 1 1 142 6 3. 35 3 1 7 6. 1 9 791 8 0. 06 2 1 2 2. 7 6 351 1 1. 66 1 1 8 7. 2 4 901 5 4. 17 0 1 3 3. 8 1 56 4 0. 84 4 1 7 6. 6 1 1 242 7 4. 55 3 1 2 2. 2 9 891 1 2. 26 2 1 8 7. 7 6 451 6 2. 86 1 1 3 3. 3 4 0 11 1 6. 37 0 1 9 8. 8 1 66 3 1. 05 4 1 2 2. 7 1 1 342 8 5. 75 3 1 8 7. 2 9 991 4 3. 46 2 1 3 3. 8 6 551 0 4. 07 1 1 9 8. 3 4 111 7 7. 57 0 1 4 4. 9 1 76 3 2. 25 4 1 8 7. 7 1 1 442 9 6. 95 3 1 3 3. 3 9 002 6 4. 66 2 1 9 8. 8 6 651 4 5. 27 1 1 4 4. 4 4 2 11 2 9. 77 0 1 0 0. 0 2 86 2 3. 45 4 1 3 3. 8 1 1 542 0 8. 16 3 1 9 8. 3 9 102 9 5. 86 2 1 4 4. 9 6 751 8 6. 47 1 1 0 0. 5 4 3 11 8 0. 08 0 1 6 5. 0 2 96 2 4. 65 4 1 9 8. 8 1 1 642 1 9. 36 3 1 4 4. 4 9 202 2 7. 07 2 1 0 0. 0 7 851 3 8. 67 1 1 6 5. 5 4 4 11 4 2. 28 0 1 1 1. 1 2 07 1 5. 85 4 1 4 4. 9 1 1 742 2 0. 66 3 1 0 0. 5 9 302 4 8. 27 2 1 6 5. 0 7 951 7 9. 87 1 1 1 1. 6 4 5 11 0 4. 48 0 1 7 6. 1 2 17 1 6. 06 4 1 0 0. 0 2 1 842 3 1. 86 3 1 6 5. 5 9 402 7 9. 47 2 1 1 1. 1 7 061 1 1. 18 1 1 7 6. 6 4 6 11 5 5. 68 0 1 2 2. 2 2 27 0 7. 26 4 1 6 5. 0 2 1 942 4 2. 07 3 1 1 1. 6 9 502 9 0. 77 2 1 7 6. 1 7 161 5 2. 38 1 1 2 2. 7 4 7 11 1 7. 88 0 1 8 7. 2 2 37 9 7. 46 4 1 1 1. 1 2 1 052 5 3. 27 3 1 7 6. 6 9 602 2 2. 97 2 1 2 2. 2 7 261 9 3. 58 1 1 8 7. 7 4 8 11 7 8. 09 0 1 3 3. 3 2 47 6 4. 47 3 1 2 2. 7 9 702 4 3. 18 2 1 8 7. 2 7 361 3 5. 78 1 1 3 3. 8 4 9 11 2 0. 39 0 1 9 8. 3 2 57 903 3-7 Model HHC-990/992/993/996/997/998 3-7. TRANSFORMER REPLACEMENT To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. 1. Using a Phillip’s head screwdriver, remove the four screws securing the front panel. 2. Pull panel down, pull connectors from the back of it, and

Figure 3-16 Figure 3-17 3-8. FOOD PROBE RECEPTACLE REPLACEMENT Figure 3-18 remove panel from unit. 3. Label wires to transformer and unplug wires to trans former. Figure 3-16. 4. Using a Phillip’s head screwdriver, remove the 2 screws securing the transformer and pull transformer from unit. Figure 3-17. 5. Install new transformer in reverse order and unit is now ready for use. To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. 1. Using a Phillip’s head screwdriver, remove the four screws securing the front panel. 2. Pull panel down, pull connectors from the back of it, and remove panel from unit. 3. Using 5/16” socket, remove the 4 nuts securing the control cover and remove cover. 4. Using a 3/8” socket, remove the nuts securing the recep tacle bracket, and pull bracket from control panel. 5. Pull connector from the PC board. Figure 3-18. 5. Install new receptacle assembly in reverse order.

3-8 903 Model HHC-990/992/993/996/997/998 3-9. RELAY REPLACEMENT To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. Checkout: 1. Using a Phillip’s head screwdriver, remove the four screws securing the front panel. 2. Pull panel down, pull connectors from the back of it, and remove panel from unit. The following checks are performed with the wall circuit breaker closed and the main power switch in the ON position. Extreme caution should be taken. Make connections before applying power, take reading, and remove power before removing meter leads, or electri cal shock could result. 3. With power reapplied, let unit start heating up, or enter the Tech Mode in Special Program Mode and check the relays in the output test. (See T-18 in the Tech Mode Section) 4. With the component energized (example: air heaters), 0 volts should show on the output side of the relay, and 12 volts on the input side. 5. With the component not energized, 208 or 240 volts should show on the output side of relay, and 0 volts on input. 6. If voltage varies from steps 4 and 5, remove power to unit, pull input wires from relay and place leads of meter onto input wires. Reapply power to unit. When unit is running, the input wires to relay should show 12 vdc volts. If this proves true, the relay is faulty and continue onto step 7. 303 3-9 Model HHC-990/992/993/996/997/998 3-9. RELAY REPLACEMENT (Continued) 7. Label wires and then remove wires from relay using a Phillip’s head screwdriver. Figure 3-19. 8. Using a Phillip’s head screwdriver, remove the 2 screws securing the relay and remove relay from unit. Figure 3-20. 9. Coat the back of the relay with the thermal joint

Figure 3-19 compound.

Figure 3-20 3-10. MODULE TOP REMOVAL Figure 3-21 Figure 3-22 Failure to use the thermal joint compound will shorten the life of the relay. 10. Install new relay in reverse order and unit is now ready for use. To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. 1. Using a Phillip’s head screwdriver, remove the module screws from the side. Figure 3-21. 2. Remove screws from front and rear panels. 3. Pull module top from module. Figure 3-22.

3-10 903 Model HHC-990/992/993/996/997/998 3-11. COOLING FAN REPLACEMENT To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. 1. Refer to section 3-10 for module top removal.

Figure 3-23 Figure 3-24 3-12. HIGH LIMIT-AIR HEATER REPLACEMENT Figure 3-25 Figure 3-26 2. Unplug connectors to the cooling fan. Figure 3-23. 3. Remove screws and nuts securing the fan and remove fan from module. Figure 3-24. 4. Install new fan in reverse order and unit is now ready for use. To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. 1. Follow the instructions in section 3-10 on removing the module top. 2. Remove wires from high limit. Figure 3-25. 3. Check across the terminals for continuity. If the unit is not heating, the circuit should be closed, or read no resistance. If high limit is defective, continue onto step 4. 4. Remove the 2 screws securing the high limit and remove high limit. Figure 3-26. 5. Install new high limit in reverse order and unit is now ready for use.

903 3-11 Model HHC-990/992/993/996/997/998 3-13. BLOWER MOTOR REPLACEMENT To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. 1. Follow the instructions in section 3-10 on removing the module top.

Figure 3-27 Figure 3-28 Figure 3-29 Figure 3-30 2. Unplug wires to blower motor. Figure 3-27. 3. Using a Phillip’s head screwdriver, remove the screws securing the blower bracket to the module. Figure 3-28. 4. Pull bracket from module. Loosen set screw on fan blade and pull blade from blower. Figure 3-29. 5. Remove the 3 nuts securing the blower to the bracket and remove blower motor. Figure 3-30. 6. Install new blower in reverse order, and unit is now ready for use.

3-12 903 Model HHC-990/992/993/996/997/998 3-14. AIR HEATER REPLACEMENT To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. 1. Follow the instructions in Module Top Removal Section on removing the module top. 2. Unplug the wires to the heater and high limit. Figure 3-31. Figure 3-31 3. Using a Phillip’s head screwdriver, remove the 4 screws securing the heater and remove heater. Figure 3-32. 4. Install new heater in reverse order and unit is now ready for use. Figure 3-32 3-15. SPEAKER REPLACEMENT To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. 1. Remove the 4 screws securing the front panel.

Figure 3-33 Figure 3-34 2. Pull connectors from back of panel and remove panel. 3. Unplug wires to speaker. Figure 3-33. 4. Using a Phillip’s head screwdriver, remove the screws securing the speaker and remove speaker. Figure 3-34. 5. Install new speaker in reverse order and unit is now ready for use.

303 3-13 Model HHC-990/992/993/996/997/998 3-16. COMPLETE PANEL OR PC BOARD REPLACEMENT To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. The complete control panel assembly can be replaced, or just the PC board. Follow steps 1 & 2 for the complete panel and continue with the remaining steps for the PC Board replace ment. Figure 3-35 1. Remove the 4 screws securing the front panel. 2. Pull connectors from back of panel and remove panel. Figure 3-35. Install complete panel in reverse order. When installing the PC board, continue to step 3.

Figure 3-36 Figure 3-37 Figure 3-38 3. Using 5/16” socket, remove the 4 nuts securing the control cover and remove cover. Figure 3-36. 4. Pull the connectors from PC Board. Figure 3-37. 5. Using 5/16” socket, remove the 8 nuts securing the PC board and remove board. Figure 3-38. 6. Install new PC board in reverse order and unit is now ready for use.

903 3-14 Model HHC-990/992/993/996/997/998 3-17. FLOAT SWITCH REPLACEMENT To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. 1. Open drain valve and empty water pan into a shallow pan or floor drain. Figure 3-39. Figure 3-39 Hot water! Do not place your hand under the drain while draining the unit. Failure to follow this warning could result in severe burns and injury. 2. Unplug wires to float switch. Figure 3-40. Figure 3-40 3. Remove nut securing the float switch and pull float switch from unit. Figure 3-41. Figure 3-41 4. Install new float switch in reverse order, making sure float switch is in upright position. Figure 3-42. 5. Unit is now ready for use.. Figure 3-42 3-15 903 Model HHC-990/992/993/996/997/998 3-18. HIGH LIMIT - WATER HEATER REPLACEMENT To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. 1. Open drain valve and empty water pan into a shallow pan or floor drain. Figure 3-43.

Figure 3-43 Figure 3-44 Figure 3-45 Hot water! Do not place your hand under the drain while draining the unit. Failure to follow this warning could result in severe burns and injury. 2. Remove all doors and racks from unit and carefully lay the unit on its back. (This step may not be necessary for units on stands.) 3. Using an 11/32” socket or wrench, remove the nuts securing the water heater cover and remove cover. Figure 3-44. 4. Remove wire from high limit. Figure 3-45. 5. Check across the terminals for continuity. If the unit is not heating, the circuit should be closed, or read no resistance. If high limit is defective, continue onto step 6. 6. Remove the 2 nuts securing the high limit and remove high limit. 7. Install new high limit in reverse order. 8. Unit is now ready for use.

903 3-16 Model HHC-990/992/993/996/997/998 3-19. WATER HEATER REPLACEMENT To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. 1. Open drain valve and empty water pan into a shallow pan or floor drain. (See Figure 3-43 on page 3-16.) Figure 3-46 Hot water! Do not place your hand under the drain while draining the unit. Failure to follow this warning could result in severe burns and injury. 2. Remove all doors and racks from unit and carefully lay the unit on its back. (This step may not be necessary for units on stands.) Figure 3-47 3. Using an 11/32” socket or wrench, remove the nuts securing the water heater cover and remove cover. (See Figure 3-44 on page 3-16.) 4. Unplug water heater and high limit wires. Figure 3-46. 5. Remove the nuts securing the water heater plate and high limit, and pull high limit, plate, insulation and water pan heater from the

Figure 3-48 Figure 3-49 unit. Figure 3-47. 6. Pull plate and insulation from unit and discard plate and insulation. Figure 3-48. 7. Pull water heater from unit. Figure 3-49.

3-17 906

3-19. WATER HEATER REPLACEMENT (Continued) Figure 3-50 Figure 3-51 Figure 3-52 Figure 3-53 Model HHC-990/992/993/996/997/998 8. Locate the aluminum, octagon plate in the kit. Make sure the surface is free of debris and place the plate over the 4 long studs. Figure 3-50. 9. Install new heater, making sure the flat side is towards the plate and the soldered wires are exposed, as shown in Figure 3-51. 10. Install the new insulation from the kit, over the water pan heater. Figure 3-52. 11. Place new cover plate from the kit, over the insulation. Figure 3-53. 12. Locate the 12 keps nuts from the kit and place them over the studs and finger-tighten. Using an 11/32” socket or wrench, snug the nuts down in a cross-fashion, but DO NOT overtighten. Overtightening the nuts could damage the coating on the heater, causing the heater to fail prematurely. 13. Reinstall high limit. 14. Reconnect high limit wires and water pan heater wires to unit. 15. Reinstall water heater cover and water supply, and unit is now ready for use.

906 3-18 Model HHC-990/992/993/996/997/998 3-20. DRAIN VALVE REPLACEMENT To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. 1. Open drain valve and empty water pan into a shallow pan or floor drain. (See Figure 3-43 on page 3-16.) Hot water! Do not place your hand under the drain while draining the unit. Failure to follow this warning could result in severe burns and injury. 2. Remove all doors and racks from unit and carefully lay the unit on its back. 3. Loosen hose clamp on water hose and pull hose from water pan. 4. Turn drain valve handle to open position (pointed outwards). 5. Using 2 wrenches, turn drain valve counterclockwise, while

Figure 3-54 holding fitting behind it. Figure 3-54. Remove drain valve assembly from unit. 6. Remove elbow from valve. (1/2-size units only) 7. Put pipe sealant on threads of elbow and install elbow in new drain valve. (1/2-size units only) 8. Put pipe sealant on threads of fitting, and install new drain valve assembly onto fitting. 9. Unit is now ready for use.

3-19 903

3-21. DOOR GASKET REPLACEMENT Figure 3-55 3-22. VENT MOTOR REPLACEMENT Figure 3-56 Figure 3-57 Model HHC-990/992/993/996/997/998 1. Pull the gasket to the side to expose the retainer screws. Figure 3-55. 2. Loosen the screws around the outside perimeter of the gasket. 3. With all the screws loose, the gasket should slide out from under the retainers. 4. Install new gasket in reverse order and unit is now ready for use. To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. 1. Follow the instructions in Module Top Removal Section on removing the module top. 2. Using a 5/16” socket or nutdriver, remove the 4 nuts securing the bracket to the back panel. Figure 3-56. 3. Label and disconnect the wires to the vent motor. 4. Using a Phillip’s-head screwdriver, remove the vent motor from the bracket. Figure 3-57. 5. Install new vent motor in reverse order.

903 3-20 Model HHC-990/992/993/996/997/998 3-23. VENT MOTOR MICROSWITCH REPLACEMENT To avoid electrical shock or property damage, move the POWER switch to OFF and disconnect main circuit breaker, or unplug cord at wall receptacle. 1. Follow the instructions in Module Top Removal Section on removing the module top. 2. Label and pull the wire connectors from the microswitch. Figure 3-58. Figure 3-58 3. Using a 3/16” socket or nutdriver, remove the nuts secur ing the microswitch and pull microswitch from unit. Figure 5-59. 4. Install new microswitch in reverse order. Figure 3-59 3-21 903

Model HHC-990/992/993/996/997/998 807 3-22

27485 120V-60hz-1ph • Wiring diagram for 120V HHC-98X & HHC-99X Model HHC-990/992/993/996/997/998

• Dashed lines indicate control module can be wired for either auto ventilation control or auto water fill • Transformer: connect wire #20 (HHC-99X) or wire #34 (HHC-98X) to primary wire 3-23 807 Model HHC-990/992/993/996/997/998 63467 807 3-24 Model HHC-990/992/993/996/997/998 27486 208/240V-60hz-1ph • Wiring diagram for 208 & 240V HHC-98X & HHC-99X • Dashed lines indicate control module can be wired for either auto ventilation control or auto water fill • Transformer: connect wire #20 (HHC-99X) or wire #34 (HHC-98X) to the appropriate primary wire (208 & 240V) 3-25 903 Model HHC-990/992/993/996/997/998 27487 230V-50hz-1ph • Wiring diagram for 230V HHC-98X & HHC-99X • Dashed lines indicate control module can be wired for either auto ventilation control or auto water fill • Transformer: connect wire #12 (HHC-99X) or wire #34 (HHC-98X) to primary wire 903 3-26 Model HHC-990/992/993/996/997/998 64384 3-27 705

4-1. INTRODUCTION 4-2. GENUINE PARTS Model HHC-990/992/993/996/997/998 SECTION 4. PARTS INFORMATION This section lists the replaceable parts of the Henny Penny HHC-99X. Use only genuine Henny Penny parts in your cabinet. Using a part of lesser quality or substitute design may result in damage to the unit, or personal injury. 4-3. WHEN ORDERING PARTS 4-4. PRICES 4-5. DELIVERY 4-6. WARRANTY 4-7. RECOMMENDED SPARE PARTS FOR DISTRIBUTORS Once the parts that you want to order have been found in the parts list, write down the following information: Example: Item Number 4 Part Number 16684 Description Cooling Fan From data plate, list the following information: Example: Product Number HHC990.0 Serial Number AW001IE Voltage 208 Volt Your distributor has a price list and will be glad to inform you of the cost of your parts order. Commonly replaced items are stocked by your local distributor and will be sent out when your order is received. Other parts will be ordered, by your distributor, from Henny Penny Corporation. All replacement parts (except lamps and fuses) are warranted for 90 days against manufacturing defects and workmanship. If damage occurs during shipping, notify the carrier at once so that a claim may be properly filed. Refer to warranty in the front of the manual for other rights and limitations. Recommended replacement parts, stocked by your distributor, are indicated with √ in the parts lists. Please use care when ordering recommended parts, because all voltages and variations are marked. Distributors should order parts based upon common voltages and equipment sold in their territory.

206 4-1 Model HHC-990/992/993/996/997/998 6 1 2 3 4 5 Quantity Item No. Part No. Description 990/996 993/998 √ 1 63419 Speaker Assembly 1 1 √ 2 63460 Transformer Assembly - 120V Pri.-24 Sec. - 1 √ 2 63459 Transformer Assembly - 208/240V Pri.-24 Sec. 1 1 √ 3 40645 Relay - 25A - Solid State 4 4 4 63832 Terminal Block Assembly 1 1 √ 5 16684 Cooling Fan Assy - 120V - 1 √ 5 16688 Cooling Fan Assy - 220V 1 1 √ 6 66879 Assy - Resistor Capacitor 1 1 √ 7* ME90-009 Relay - 240 VAC Coil - 30 Amp - CE 1 1 √ recommended parts *not shown 4-2 707

2 8 6 1 4 5 Model HHC-990/992/993/996/997/998 3 7 Quantity

Item No. Part No. Description 990/996 993/998 √ 1 14865 Kit - Control Board - 990 - 5 CDT 1 - √ 1 14866 Kit - Control Board - 990 - 15 CDT 1 - √ 1 14867 Kit - Control Board - 992/993 - 5 CDT - 1 √ 1 14868 Kit - Control Board - 996 - 5 CDT 1 - √ 1 14869 Kit - Control Board - 996 - 15 CDT 1 - √ 1 14870 Kit - Control Board - 997/998 - 5 CDT - 1 √ 2 63464 Power Switch 1 1 3 61726 Decal - Control HHC-990 1 - 3 61757 Decal - Control HHC-990 - 5 CDT 1 - 3 61759 Decal - Control HHC-996 - 5 CDT 1 - 3 61733 Decal - Control HHC-993 - 1 3 61734 Decal - Control HHC-996 1 - 3 61735 Decal - Control HHC-998 - 1 4 28816 Assy - 990 Door - RH Top 1 or 2 - 4 28817 Assy - 990 Door - RH Bottom 1 or 2 - 4 28818 Assy - 990 Door - LH Top 1 or 2 - 4 28819 Assy - 990 Door - LH Bottom 1 or 2 - 4 27033 Assy - 993 Door - RH - 1 or 2 4 27034 Assy - 993 Door - LH - 1 or 2 4 32774 Assy - 993 Glass Door - RH - 1 or 2 4 32775 Assy - 993 Glass Door - LH - 1 or 2 4 70733 Assy - 996 Door 2 or 4 - 4 70734 Assy - 998 Door - 1 or 2 5 14272 Kit - Door Handle 2 or 4 2 6 64124 Assy - Receptacle - Food Probe 1 1 √ 6 37420 Receptacle only - Food Probe 1 1 7 14271 Kit - Door Hinge 4 or 8 4 8 56585 Assy - Stud - Probe Guard 1 1 9* 27149 Door Stops (RH-RH & LH-LH pass thru units) 4 - 10* 14327 Kit - HHC992 Stacking - 1 10* 14328 Kit - HHC997 Stacking - 1 11* 64355 Clip - Food Probe 1 1 √ recommended parts/*not shown 1006 4-3

12 11 3 4 Model HHC-990/992/993/996/997/998 6 7 1 2 5 8 Quantity

Item No. Part No. Description 990/996 993/998 √ 1 18364 Fuse Holder Assembly (120V units have only 1 fuse) 2 2 √ 1 EF02-007 Fuse - 15 Amp 2 2 √ 1 EF02-006 Fuse Holder 2 2 2 63927 Power Cord Assembly - 120V-50A - 1 2 63928 Power Cord Assembly - 120V-20A - 1 2 63929 Power Cord Assembly - 208/240V-30A - 1 2 63930 Power Cord Assembly - 208/240V-20A 1 1 2 63931 Power Cord Assembly - 208/240V-15A 1 1 √ 3 64285 Air Heater Assy-1000W-104-120V(208V units) 2 - (includes 63815 gasket) √ 3 64128 Air Heater Assy-900W-120V - CE 2 - (includes 63815 gasket) √ 3 64126 Air Heater Assy-600W-120V (includes 63815 gasket) - 2 √ 4 63363 Blower - Motor 120V - 1 √ 4 63362 Blower - Motor 208V 1 1 √ 5 18201 Sensor - High Limit - 335Deg. 2 2 √ 5 59272 Sensor - High Limit - 375Deg. - CE (manual reset) 2 2 √ 6 63829 Assy - Vent Motor - 110/220 1 1 √ 7 64098 Assy - Sealed Switch and Actuator 1 1 8 59496 Stud Assy- Motor Mounting Plate 1 1 9* 63814 Gasket - Plate - Motor Mounting 1 1 √ 10* 51068 Assy - EMC Filter Board 1 1 11 63461 Vent Hose-Intake 1 1 12 63462 Vent Hose-Exhaust 1 1 4-4 √ recommended parts/*not shown 612 Model HHC-990/992/993/996/997/998 1 2 Quantity Item No. Part No. Description 990/996 993/998 √ 1 14390 Kit - Humidity Sensor (before 4/1/2005) 1 1 √ 1 140135 Kit - Humidity Sensor (4/1/2005 & after) 1 1 √ 2 64283 Probe-Air Temp 1 1 √ 3* 14391 Kit - Calibration Board 1 1 √ recommended parts *not shown 512 4-5

4 6 2 3 4 Model HHC-990/992/993/996/997/998 7 8 5 1 9 Quantity

Item No. Part No. Description 990/996 993/998 1 27155 Caster 2 2 2 63389 Valve - Drain w/Handle 1 1 3 FP01-131 Male Connector - 5/8 Tube 1 1 4 27154 Caster - Locking 2 2 5 64154 Check Valve 1 or 2 1 6 63463 Water Pan Hose 2 or 4 2 7 SC01-039 Screw - 1/4-20x1 Hex Hd C 16 16 8 LW01-002 Lockwasher - Split Ring 1/4 S 16 16 9 64351 Cover - Water Pan Heater 1 1 9 21031 Cover - Water Pan Heater - CE 1 1 10* FP01-136 Fitting - 1/2 Barb-3/4 Male Hose - 1 (allows garden hose drain for stacked units) 11* FP01-132 Male Hose 3/4” Hose Thread - 1 (allows garden hose drain for stacked units) 12* 64289 Drain Tube - Cabinet - 1 (drain tube for top unit on stacked units) *not shown 4-6 705 Model HHC-990/992/993/996/997/998 1 4 2 5 3 6 Quantity Item No. Part No. Description 990/996 993/998 √ 1 14631 Kit - Water Pan Heater - 120V - 1 √ 1 14632 Kit - Water Pan Heater - 208V 1 1 √ 1 14633 Kit - Water Pan Heater - 240V 1 1 2 71130 Spacer - Water Heater 1 1 3 68130 Insulator - Water Heater 1 1 4 67524 Plate - Water Heater Backing 1 1 5 NS02-007 Nut Hex Keps - #8-32 C 12 12 √ 6 63831 Hi Limit - Water Pan 1 1 √ 6 64297 Hi Limit - Water Pan - CE (manual reset) 1 1 √ recommended parts 906 4-7 Model HHC-990/992/993/996/997/998

12 3 4 2 Quantity

Item No. Part No. Description 990/996 993/998 √ 1 25643 Gasket - Door - 990 2 or 4 - √ 1 25793 Gasket - Door - 993 - 2 √ 1 28147 Gasket - Door - 996 2 or 4 - √ 1 28143 Gasket - Door - 998 - 2 2 25957 Assy. - 993 Air Duct - 2 2 28128 Assy. - 998 Air Duct - 2 2 27895 Assy. - 990 Air Duct - Upper - 15 tray 2 - 2 27811 Assy. - 990 Air Duct - Lower - 15 tray 2 - 2 30880 Assy. - 990 Air Duct - Lower - 14 tray(used with 27811) 2 - 2 27894 Assy. - 990 Air Duct - Upper - 10 tray 2 - 2 27825 Assy. - 990 Air Duct - Lower - 10 tray 2 - 2 28729 Assy. - 990 Air Duct - Upper - 8 tray 2 - 2 28728 Assy. - 990 Air Duct - Lower - 8 tray 2 - 2 52345 Assy. - 990 Air Duct - Upper - KFC 2 - 2 52346 Assy. - 990 Air Duct - Upper - KFC 2 - 2 28129 Assy. - 996 Air Duct - Upper 2 - 2 28130 Assy. - 996 Air Duct - Lower 2 - 2 28133 Pan Bracket Weldment 22 - 2 34519 Duct - 996 - Air - Upper - Knotts Berry 2 - 2 34517 Duct - 996 - Air - Lower - Knotts Berry 2 - 2 34563 Assy. - Slide and Connectors - Knotts Berry 30 - 2 34550 Assy. - 996 - Air Duct - Upper 2 - 2 34545 Assy. - 996- Air Duct - Lower 2 - √ 3 67297 Switch - Float Assembly 1 1 4 63525 Assy-Water Pan Cover & Ring (concentration ring) 1 1 4 SC01-076 Screw - #8-32 x 1/4 PH THD S 8 8 4 ME50-048 Standoff - .25 dia. x .63 lg. #8-32 SS 4 4 √ recommended parts 4-8 206


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