Duke IRHS22 User manual

Service Manual

11/18/2015

INFRARED

HEATSINK™

HOLDING UNIT

Includes Standalone,

Kitchen Minder and

VISOR models

MODELS

IRHS22

IRHS23

IRHS24

IRHS34

IRHS42

Reproduction without written permission is prohibited. Duke is a registered trademark of the Duke Manufacturing Co.

Duke Manufacturing Co.

2305 North Broadway • St. Louis, MO 63102-1405

Phone: 314-231-1130 • Toll Free: 1-800-735-3853 • Fax: 314-231-5074

[email protected] • www.dukemfg.com

Please read this manual completely before attempting

to install, operate or service this equipment.

This document is prepared for trained Duke service technicians. It is not to be used by anyone not properly

qualied to perform these procedures.

This Service Manual is not all encompassing. If you have not been trained on servicing this product, be sure

to read the manual completely before attempting servicing. Be sure all necessary tools, test equipment,

and skills are available. Those procedures for which you do not have the proper skills and test equipment

must be performed only by a qualied Duke trained service technician.

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IMPORTANT WARNING AND SAFETY INFORMATION

READ THIS MANUAL THOROUGHLY BEFORE OPERATING, INSTALLING OR PERFORMING MAINTENANCE

ON THE EQUIPMENT.

READ THIS MANUAL THOROUGHLY BEFORE OPERATING, INSTALLING OR PERFORMING

MAINTENANCE ON THE EQUIPMENT

FAILURE TO FOLLOW INSTRUCTIONS IN THIS MANUAL 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.

DO NOT OPERATE THIS EQUIPMENT WITHOUT PROPERLY PLACING AND SECURING ALL

COVER AND ACCESS PANELS.

IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN

CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATING AND MAINTENANCE

INSTRUCTIONS THOROUGHLY BEFORE INSTALLING THIS EQUIPMENT.

FOR YOUR SAFETY







CAUTION

Observe the following:

• Provideandmaintainadequateminimumclearancesfromallwallsandcombusblematerials.

• Provideandmaintainadequateclearanceforairopenings.

• Keeptheequipmentareafreeandclearofcombusblematerial.

• Operateequipmentonlyonthetypeofelectricityindicatedonthespecicaonplate.

• Retainthismanualforfuturereference.

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TABLE OF CONTENTS

SPECIFICATIONS........................................................................................................................................5

IRHS22 .............................................................................................................................................. 5

IRHS23 .............................................................................................................................................. 6

IRHS24 .............................................................................................................................................. 7

IRHS34 .............................................................................................................................................. 8

IRHS42 .............................................................................................................................................. 9

REMOVALANDREPLACEMENTOFPARTS..............................................................................................10

 EQUIPMENTUSEDINTHESEINSTRUCTIONS...................................................................................10

 ELECTRICALLOCKOUT/TAGOUTPROCEDURE...................................................................................10

 ESDWRISTSTRAP............................................................................................................................. 11

 DECKASSEMBLYCOMPONENTS.......................................................................................................12

  MENUBARS.............................................................................................................................. 12

  KEYPADDISPLAYS.......................................................................................................................14

  RTD(TEMPERATURE)SENSORS.................................................................................................16

HIGH LIMIT THERMOSTATS........................................................................................................ 18

HEAT ELEMENTS........................................................................................................................ 21

  EMITTER(IRBULB)SOCKETS.....................................................................................................24

  EMITTERS(IRBULBS).................................................................................................................27

 CONTROLCOMPARTMENTCOMPONENTS–STANDALONE&KITCHENMINDERMODELS(only)...28

  POWERSWITCH......................................................................................................................... 28

  USBADAPTER............................................................................................................................28

  DAYPARTSWITCH.......................................................................................................................29

  RELAYS(SmartPowerModules)................................................................................................29

  CONTROLLER.............................................................................................................................30

TRANSFORMER..........................................................................................................................30

  RTDBOARD................................................................................................................................31

FUSES AND FUSE HOLDER.........................................................................................................32

 CONTROLCOMPARTMENTCOMPONENTS–KITCHENMINDERMODEL(only)...............................33

  KITCHENMINDERMASTERBOARD(ifinstalled).......................................................................33

  KITCHENMINDERADAPTERBOARD(ifinstalled)......................................................................34

  MOUNTINGPLATE(ifinstalled).................................................................................................35

  COUPLERS(ifinstalled).............................................................................................................. 36

 CONTROLCOMPARTMENTCOMPONENTS–VISORMODEL(only).................................................37

  12VPOWERCONTROLBOARD.................................................................................................37

  POWERCONTROLBOARD–ACM..............................................................................................38

  POWERCONTROLBOARD–103M............................................................................................39

  POWERCONTROLBOARD–TRIACDRIVE.................................................................................40

FUSE HOLDER AND FUSES.........................................................................................................41

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TROUBLESHOOTING&DIAGNOSTICS.....................................................................................................42

 IRHSTROUBLESHOOTINGFLOWCHART..........................................................................................42

 IRHSTROUBLESHOOTINGGUIDE.....................................................................................................43

 IRHSCOMPONENTTECHNICALSPECIFICATIONS.............................................................................44

OPERATIONS........................................................................................................................................... 47

 OPERATINGPROCEDURES................................................................................................................ 47

  OPERATIONS..............................................................................................................................47

   ChangingDayparts.............................................................................................................. 48

   DisplayLink,HoldTime,orTemperature............................................................................49

  DIAGNOSTICS.............................................................................................................................50

   CheckingHeatSinkTemperature........................................................................................50

   CheckingIRBulbFuncon.................................................................................................. 50

   CheckingProductSengs(viaUSBle).............................................................................50

   ErrorCodes......................................................................................................................... 51

   TemperatureCheckProcedure...........................................................................................51

CLEANING&ROUTINEMAINTENANCE..................................................................................................52

 CLEANING........................................................................................................................................52

 RECOMMENDEDSUPPLIES...............................................................................................................52

 DAILYINSPECTIONCHECKLIST..........................................................................................................52

 DAILYCLEANINGPROCEDURES........................................................................................................ 53

WEBSITEPROGRAMMING......................................................................................................................54

WIRINGSCHEMATICS.............................................................................................................................58

 IRHSDECKWIRING........................................................................................................................... 58

IRHS22 Wiring DIAGRAM.................................................................................................................59

IRHS23 WIRING DIAGRAM...............................................................................................................60

IRHS24 WIRING DIAGRAM...............................................................................................................61

IRHS34 WIRING DIAGRAM...............................................................................................................62

IRHS42 WIRING DIAGRAM...............................................................................................................63

 VISORINTERFACECABLEWIRINGDIAGRAM...................................................................................64

 KITCHENMINDERCONNECTIONS....................................................................................................65

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SPECIFICATIONS

IRHS22

Before Serial# 10140480

(10/1/14)

As of Serial# 10140480

Shipping Weight 125lbs/56.7kg 110lbs/49.9kg

Model Electrical Plug H W D H W D

IRHS22-208 208V ~ 12 A, 50/60 Hz NEMA6-15P

14.4in/

36.6cm

19.3in/

49.0cm

20.1in/

51.1cm

13.3in/

33.8cm

19.3in/

49.0cm

20.1in/

51.1cm

IRHS22-230 230V ~ 12 A, 50/60 Hz

SHUKO,16AMP

(as of 11/3/14)IEC,16AMP

IRHS22-240 240V ~ 12 A, 50/60 Hz NEMA6-15P

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IRHS23

Up to Serial# 101413198

(10/20/14)

Aer SN# 101413198

Shipping Weight 160lbs/72.6kg 143lbs/64.9kg

Model Electrical Plug H W D H W D

IRHS23-208 208V ~ 12 A, 50/60 Hz NEMA6-15P

14.4in/

36.6cm

26.4in/

67.1cm

20.1in/

51.1cm

13.3in/

33.8cm

26.4in/

67.1cm

20.1in/

51.1cm

IRHS23-230 230V ~ 12 A, 50/60 Hz

SHUKO,16AMP

(as of 11/3/14)IEC,16AMP

IRHS23-240 240V ~ 12 A, 50/60 Hz NEMA6-15P

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IRHS24

Before Serial# 10140545

(10/3/14)

As of Serial# 10140545

Shipping Weight 195lbs/88.4kg 181lbs/82.1kg

Model Electrical Plug H W D H W D

IRHS24-208 208V ~ 12 A, 50/60 Hz NEMA6-15P

14.4in/

36.6cm

33.4in/

84.8cm

20.1in/

51.1cm

13.3in/

33.8cm

33.4in/

84.8cm

20.1in/

51.1cm

IRHS24-230 230V ~ 12 A, 50/60 Hz

SHUKO,16AMP

(as of 11/3/14)IEC,16AMP

IRHS24-240 240V ~ 12 A, 50/60 Hz NEMA6-15P

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IRHS34

Before Serial# 10140032

(10/1/14)

As of Serial# 10140032

Shipping Weight 275lbs/124.7kg 243lbs/110.2kg

Model Electrical Plug H W D H W D

IRHS34-208 208V ~ 16 A, 50/60 Hz NEMA6-20P

20.9in/

53.1cm

33.4in/

84.8cm

20.1in/

51.1cm

19.3in/

49.0cm

33.4in/

84.8cm

20.1in/

51.1cm

IRHS34-230 230V ~ 16 A, 50/60 Hz

SHUKO,16AMP

(as of 11/3/14)IEC,16AMP

IRHS34-240 240V ~ 16 A, 50/60 Hz NEMA6-20P

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IRHS42

Shipping Weight 187lbs/84.8kg

Model Electrical Plug H W D

IRHS42-208 208V ~ 12 A, 50/60 Hz NEMA6-15P

25.3in/

64.3cm

19.3in/

49.0cm

20.1in/

51.1cm

IRHS42-230 230V ~ 12 A, 50/60 Hz

SHUKO,16AMP

(as of 11/3/14)IEC,16AMP

IRHS42-240 240V ~ 12 A, 50/60 Hz NEMA6-15P

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REMOVAL AND REPLACEMENT OF PARTS

EQUIPMENT USED IN THESE INSTRUCTIONS

• Phillipsscrewdriver

• #1precisionscrewdriver

• Flat-headscrewdriver

• Needle-nosepliers

• 11/16"open-endwrench

• 11/32"nutdriverorsocket

• 1/4"nutdriverorsocket

• Tiewraps

• ESDWristStrap

• Aluminumtape

• Ohmmeter

• Heattransfercompound

• Cleangloves/cloths/towels

ELECTRICAL LOCKOUT/TAGOUT PROCEDURE

WARNING

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 PROPERTY

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:

1. Inelectricalbox,placeappliancecircuitbreaker

intoOFFposion.

2. Placealockorotherdeviceonelectricalboxcover

topreventsomeonefromplacingcircuitbreaker

ON.

3. Placeatagonelectricalboxcovertoindicatethat

appliancehasbeendisconnectedforserviceand

powershouldnotberestoredunltagisremoved

bymaintenancepersonnel.

4. Disconnectappliancepowercordfromelectrical

outlet.

5. Placeatagonthecordtoindicatethatunithas

beendisconnectedforserviceandpowershould

notberestoredunltagisremoved.

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ESD WRIST STRAP

Electrostac Discharge (ESD) is one of the biggest

dangerstocomponentsinelectronicdevices.AnESD

wriststrap allowsanyaccumulatedstaccharge to

dispersesafelythroughitscable,ratherthanthrough

stac-sensivecomponentssuchas unitcomputer-

relatedcomponents.

1. PlacetheESDwriststraparoundyourwrist.The

wriststrapshouldbenexttoyourskin,soitneeds

tobeplacedunderanyclothes.

2. Tightenthewriststrapsothattheaachedmetal

platemaintainsgoodcontactwithyourskin.Do

notoverghtenasthewriststrapshouldnotbe

uncomfortable.

3. Connect the cable to the wrist strap if it is

disconnected.Thecableshouldbesecurelyclipped

inplacetomaintainagoodconnecon.

4. Placetheunit’sPowerSwitchintheOFFposion

andfollowtheproperLockout/Tagoutprocedures.

5. Connectthealligatorclipontheotherendofthe

cabletoametalsurfaceontheunit.Thiscreatesa

paththroughwhichanybuilt-upstacchargecan

safelyowwithoutcausinganydamage.Abuilt-in

highvalueresistorensuresthechargeleaksaway

inacontrolledmanner,andprotectstheuser.

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DECK ASSEMBLY COMPONENTS

MENU BA RS

TheMenuBarsholdtheKeypadDisplaysthatcontrol

andmonitortheperformanceofeachheangwell.The

quantyvaries(dependingonmodel)andarelocated

onthefrontandbackfacesoftheunit.

TOOLS REQUIRED: Phillips screwdriver; Flat-head

screwdriver

1. Placetheunit’sPowerSwitchintheOFFposion

andfollowtheproperLockout/Tagoutprocedures.

2. RemoveandretainthescrewssecuringtheControl

SideCoverandremovethecover.

3. RemoveandretainscrewsoftheaectedMenu

Barandpullawayfromthefaceoftheunit.Itis

notnecessary,butrecommended,tocompletely

removetheMenuBarfromtheunit.

4. Mark and disconnect the aected Menu Bar’s

molexconnectorinsidethecontrolcompartment.

5. If it is necessary to reuse the exisng Keypad

DisplaysinareplacementMenuBar:

a. Removeandretainthetwo(2)screwssecuring

theMenuBarBackChannelandpryoutofthe

formerMenuBar.

b. AKeypad Spacer is aachedto the rear of

eachKeypadDisplaywithdouble-sidedtape.

CarefullypryoandremovetheKeypadSpacer

fromtheaectedKeypadDisplay(s).Thiswill

free-uptheMenuBarHarness.

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c. Disconnect the aected Keypad Display(s)

electrical connector from the Menu Bar

Harness.

d. TheKeypadDisplaysareaachedtotheMenu

Barwithdouble-sidedgluedots.Carefullypry

oandremovetheaectedKeypadDisplay

fromtheMenuBar.

e. Carefully scrape any remaining adhesive

residuefromtheinsideoftheMenuBar.

RESTORE

6. Carefully place the KeypadDisplaysinplaceon

theinteriorsideofthereplacementMenuBar.If

reusingtheKeypadDisplays,itmaybenecessary

touseaddionaldouble-sidedtapetosecurethe

KeypadDisplaystotheMenuBar.

7. Connect the replacement Menu Bar Harness’

molexconnectorinthecontrolcompartment.

8. ReplacetheKeypadSpacer,overtheMenu Bar

Harness,totherearoftheKeypadDisplay(s).

9. ReinstallMenuBarBackChannelusingitsscrews.

10. ReinstalltheMenuBarusingitsscrews.

11. ReplacetheControlSideCoverandsecurewith

itsscrews.

12. Restore power to the unit and test for proper

funcon.

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KEYPAD DISPLAYS

The Keypad Displays control and monitor the

performanceofeachheangwell.Theyarelocated

inside of the Menu Bar(s) and the quanty varies

(dependingonmodel).

TOOLS REQUIRED: Phillips screwdriver; Flat-head

screwdriver

1. Placetheunit’sPowerSwitchintheOFFposion

andfollowtheproperLockout/Tagoutprocedures.

2. RemoveandretainthescrewssecuringtheControl

SideCoverandremovethecover.

3. Disconnect the affected Menu Bar’s molex

connectorinsidethecontrolcompartment.

4. Remove and retain screws of the Menu Bar

containingtheaectedKeypadDisplayandpull

awayfromthefaceoftheunit.Itisnotnecessary,

but recommended, to completely remove the

MenuBarfromtheunit.

5. Remove and retain the screws securing the Menu

BarBackChannelfromthefrontoftheMenuBar

andpryoutoftheMenuBar.

6. AKeypadSpacerisaachedtotherearofeach

KeypadDisplaywithdouble-sidedtape.Carefully

pryoandremovetheKeypadSpacerfromthe

aectedKeypadDisplay(s).Thiswillfree-upthe

MenuBarHarness.

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7. Disconnect the affected Keypad Display(s)

electricalconnectorfromtheMenuBarHarness.

8. The KeypadDisplaysareaached to the Menu

Bar with double-sided glue dots. Carefully pry

oandremovetheaectedKeypadDisplayfrom

theMenuBar.

9. Carefullyscrapeanyremainingadhesiveresidue

fromtheinsideoftheMenuBar.

RESTORE:

10. Peelotheadhesivecoverfromthegluedotsand

placeonthereplacementKeypadDisplay.

11. Peel o the other adhesive cover from the glue

dotsandcarefullyposionthereplacementKeypad

DisplayinplaceontheinteriorsideoftheMenuBar.

12. ReconnecttheaectedKeypadDisplay(s)electrical

connectortotheMenuBarHarness.

13. ReplacetheKeypadSpacer,overtheMenuBar

Harness,totherearoftheKeypadDisplay(s).

14. Reinstall the Menu Bar Back Channel using its

screws.

15. ReinstalltheMenuBarusingitsscrews.

16. Restore power to the unit and test for proper

funcon.

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RTD (TEMPERATURE) SENSORS

The RTD Sensors monitor the temperature of the

heangwells.Theyareaxedtotheboom-centerof

eachHeatElement,andthequantyvaries(depending

onmodel).

TOOLS REQUIRED: Phillips screwdriver; Aluminum

tape; Tie wraps

1. Placetheunit’sPowerSwitchintheOFFposion

andfollowtheproperLockout/Tagoutprocedures.

2. Removeanypansandcoversonthelevel(s)being

removed.

3. RemoveandretainthescrewssecuringtheTop

Panelandremovethecover.

4. RemoveandretainthescrewssecuringtheControl

SideCoverandremovethecover.

NOTE: If the RTD Sensor to be replaced is on a lower

level, start from the top and repeat the

following four steps for each level above the

desired level.

5. Mark,removetheewraps,anddisconnectthe

wires for the RTD Sensors from the RTD board in

theControlCompartment.

6. Mark, remove the e wraps, and disconnect

the wires for the Emier (IR Bulb) Sockets and

Heat Elements from the Relays in the Control

Compartment.

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7. Removethefour(4)screws(2infront,2inback)

securingthelinerdeckassemblytotheunit.

8. Carefully li the enreliner deck assembly out

throughthetopoftheunit.Thismayrequiretwo

people, depending on the locaon of the IRHS

unit.Thoughnotrequiredtodoso,removingthe

level’sIRglassframeassembly(instruconsare

containedintheEmierinstrucons)willlighten

theweightofthelinerdeckassemblyandmake

iteasierforonepersontoaccomplishthistaskif

theIRHSislocatedinanelevatedlocaonorhas

limitedaccess.

NOTE: It will be necessary to feed the RTD Sensor,





not to damage any of the wires.

9. Invertthelinerdeckassemblyupside-down,then

removeandretaintheinsulaon.

10. TheRTDSensorisaachedtotheheatelement

withdouble-sidedadhesivetapeandcoveredwith

aluminumtape.Carefullypryoandremovethe

aectedRTDSensorfromtheHeatElement.

RESTORE:

11. Peel off the adhesive tape cover from the

replacement RTD Sensor and press in place on

theheatelement.Replacealuminumtapecover.

12. Feed the Heat Element and RTD Sensor wires in the

direconofandthroughthecontrolcompartment

bushingsandreplacetheinsulaon.

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13. Invert the liner deck assembly right-side up.

WhilefeedingtheRTDSensor,Emier,andHeat

Element wires through the appropriate control

compartmentbushings, carefully slide the liner

deckassemblyintotheunit,takingcauonnot

todamageanyofthewires.

NOTE: This may require two people, depending on



14. Reconnectandewrapallpreviouslydisconnected

wiresandconnectorsinthecontrolcompartment.

15. ReplacetheControlSideCoverandsecurewith

itsscrews.

16. ReplacetheTopPanelandsecurewithitsscrews.

17. Restore power to the unit and test for proper

funcon.

HIGH LIMIT THERMOSTATS

TheHighLimitThermostatsmonitorwelltemperatures

andservesasanemergencycircuitinterrupterincase

ofinadvertentoverheang.Thereisoneperlevel,and

areaxedtotheboom-centerofeachheatsink.

TOOLS REQUIRED: Phillips screwdriver; Heat transfer

compound; Tie wraps

1. Placetheunit’sPowerSwitchintheOFFposion

andfollowtheproperLockout/Tagoutprocedures.

2. Removeanypansandcoversonthelevel(s)being

removed.

3. RemoveandretainthescrewssecuringtheTop

Panelandremovethecover.

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4. RemoveandretainthescrewssecuringtheControl

SideCoverandremovethecover.

NOTE: If the High Limit Thermostat to be replaced is

on a lower level, start from the top and repeat

the following four steps for each level above

the desired level.

5. Mark,removetheewraps,anddisconnectthe

wires for the RTD Sensors from the RTD board in

theControlCompartment.

6. Mark, remove the e wraps, and disconnect

the wires for the Emier (IR Bulb) Sockets and

Heat Elements from the Relays in the Control

Compartment.

7. Removethefour(4)screws(2infront,2inback)

securingthelinerdeckassemblytotheunit.

8. Carefully li the enreliner deck assembly out

throughthetopoftheunit.Thismayrequiretwo

people, depending on the locaon of the IRHS

unit.Thoughnotrequiredtodoso,removingthe

level’sIRglassframeassembly(instruconsare

containedintheEmierinstrucons)willlighten

theweightofthelinerdeckassemblyandmake

iteasierforonepersontoaccomplishthistaskif

theIRHSislocatedinanelevatedlocaonorhas

limitedaccess.

NOTE: It will be necessary to feed the RTD Sensor,





not to damage any of the wires.

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9. Invertthelinerdeckassemblyupside-down,then

removeandretaintheinsulaon.

10. Markanddisconnectthespadeterminalsforthe

aectedHighLimitThermostat.

11. Removeandretainthetwo(2)11/32"nutssecuring

theHighLimitThermostattotheheatsinkand

removetheHighLimitThermostat.

12. Cleanthemounngsurfaceofanyresidualheat

transfercompound.

RESTORE:

13. Applyheattransfercompoundtothemounng

surfaceofthereplacementHighLimitThermostat.

14. InstallthereplacementHighLimitThermostatand

securewithitsnuts.

15. Reattach the High Limit Thermostat spade

terminals.Besuretoreapplythetapethathelps

secure the spade terminals to the High Limit

Thermostat.

16. Feed the Heat Element and RTD Sensor wires in the

direconofandthroughthecontrolcompartment

bushingsandreplacetheinsulaon.

17. Invert the liner deck assembly right-side up.

WhilefeedingtheRTDSensor,Emier,andHeat

Element wires through the appropriate control

compartmentbushings, carefully slide the liner

deckassemblyintotheunit,takingcauonnot

todamageanyofthewires.

NOTE: This may require two people, depending on



18. Reconnectandewrapallpreviouslydisconnected

wiresandconnectorsinthecontrolcompartment.

19. ReplacetheControlSideCoverandsecurewith

itsscrews.

20. ReplacetheTopPanelandsecurewithitsscrews.

21. Restore power to the unit and test for proper

funcon.

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Duke IRHS22 User manual

Duke IRHS22 User manual

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