WELBILT 8197929 Crisp and Ready Serving Station Instruction Manual

Serving Quality on Demand
CrispyMax™
Crisp and Ready Serving Station
Service Manual

8197929 Crisp and Ready Serving Station

Safety Notices
Warning
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.
DANGER
Do not install or operate equipment that has been misused, abused, neglected, damaged, or altered/ modified from that of original manufactured specifications.
DANGER
Keep power cord AWAY from HEATED surfaces. DO NOT immerse power cord or plug in water. DO NOT let power cord hang over edge of table or counter.
Warning
Authorized Service Representatives are obligated to follow industry standard safety procedures, including, but not limited to, local/national regulations for disconnection / lock out / tag out procedures for all utilities including electric.
Warning
Do Not Store Or Use Gasoline Or Other Flammable Vapors Or Liquids In The Vicinity Of This Or Any Other Appliance. Never use flammable oil soaked cloths or combustible cleaning solutions, for cleaning.
Warning
This product contains chemicals known to the State of California to cause cancer and/or birth defects or other reproductive harm. Operation, installation, and servicing of this product could expose you to airborne particles of glasswool or ceramic fibers, crystalline silica, and/or carbon monoxide. Inhalation of airborne particles of glasswool or ceramic fibers is known to the State of California to cause cancer. Inhalation of carbon monoxide is known to the State of California to cause birth defects or other reproductive harm.
Warning
Do not use electrical appliances or accessories other than those supplied by the manufacturer.
Warning
Use caution when handling metal surface edges of all equipment.
Warning
This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision concerning use of the appliance by a person responsible for their safety. Do not allow children to play with this appliance.
Warning
DO NOT use this product near water – for example, near a kitchen sink, in a wet basement, near a swimming pool, or similar locations.
Notice
Proper installation, care and maintenance are essential for maximum performance and trouble-free operation of your equipment. Visit our website www.mercoproducts.com for manual updates, translations, or contact information for service agents in your area.

General Information

Overview
The Merco Crispy Max is designed to warm prepared fried foods with a flow of heated air.
It’s operated by a single switch. A small round LED above the power switch indicates the status of the unit.

Solid GREEN light: Normal Operation
Blinking GREEN light: Preheating
Blinking YELLOW light: Clean Filter; refer to User Manual or Scan QR Code on Unit
Blinking RED light: Error; CALL SERVICE 877.392.7770
The heaters in 1 and 2 row models are 120V.
The heaters in 3 row models are 208-240V.
One control board is present in 1 and 2 row units.
Two control boards are present in 3 row units.
The control boards are identical. 1 and 2 lane units do not require jumpers. In 3 lane units the primary and secondary boards are set with a jumper. Below is a board with a jumper in the secondary position.

There are no power supplies or transformers; the control board generates DC power for fans and switch. Line voltage is used to operate the heater assembly
Component Identification
Side panels must be removed to access motor/ heater/control compartment.

Steps For Component Removal

1. Remove divider(s) if present.

2. Remove food tray.

3. Remove crumb tray.

4. Assemble in reverse order.
   NOTE: Always allow sufficient time for unit to cool down prior to moving unit. Failure to do so could damage the heating element inside the unit.

5. Ensure the food tray is inserted correctly. The front edge should be flush with the cabinet. Correct placement of the food tray.Incorrect placement of the food tray. Front edge is too high. Incorrect placement of the food tray. Food tray is rotated 180˚

Troubleshooting

for service.
Excessive time to reach temperature.| Improper food tray installation / Blocked airflow at rear of unit / Dirty or plugged air filter| Install food tray properly / Remove any airflow blockages / Clean and dry air filter then reinstall.
Low airflow volume.| Improper food tray installation/ Blocked airflow at rear of unit / Dirty or plugged air filter (if applicable)| Install food tray properly / Remove any airflow blockages / Clean and dry air filter then reinstall (if applicable).
Airflow works but no heat.| Internal wiring.| Check wiring.
Degrading performance.| Grease or debris build-up.| Clear air intakes at front and rear of unit.

Sequence Of Operation

Power Supply| Electrical power is supplied to the unit by a 3 conductor service for single phase. Black conductor is hot.
White conductor is neutral.
Green and yellow conductor is ground.
Power is permanently supplied to one of the normally open contacts of the main switch also to one side of the normally open contacts of the main heater relay.
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Heating Circuit| Closing the main power switch feeds power through the normally closed high limit thermostat to the coil of the main relay. Its contacts now close supplying power to the main heater. Also for air circulation power is supplied to the main fan motor.

This unit has intelligent controls, software and a feedback loop that will automatically adjust for consistent performance across a range of voltages (110-120V / 200-240V, depending on the model)
When checking control boards, ensure that all three (3) voltage LEDS are illuminated.

LED Troubleshooting Chart

Front LED| Control Board LED| Description| Probable Cause| Possible Parts Required| Service Procedure Status
---|---|---|---|---|---
Solid Green| Orange flashes -IO COMM (2 & 3 Lane only)| Normal Operation| N/A| N/A| N/A
Flashing Green| N/A| Preheating| N/A| N/A| N/A
Flashing Yellow| N/A| Filter Clog Warning (if applicable)| Filter may be clogged with debris (if applicable).| Filter (if applicable)| Check and clean filter (if applicable). Replace if necessary (if applicable).
Flashing Red| N/A| Menu or Software update warning| Menu or Software update failed| N/A| Reload menu or software.
Flashing Red/ Green/ Yellow| N/A| Menu or Software update in process| N/A| N/A| N/A
Two (2) -Red flashes and a Three (3) second pause| One (1) -Zone 1 or 2 Error flash and a Three (3) second pause| Temperature Low Error -Temperature is < 25˚F below the setpoint for > 2 min.| Heater, AC Harness or Control Board failure| Heater, AC Harness, Control Board| Check heater, AC Harness or control board operation. Replace failed part
Two (2)- Red flashes and a Three (3) second pause| Two (2)- Zone 1 or 2 error flash and a Three (3) second pause| Temperature High Error -Temperature is > 25˚F above the setpoint for > 2 min.| Heater, AC Harness or Control Board failure| Heater, AC Harness, Control Board| Check heater, AC Harness or control board operation. Replace failed part.
Three (3)- Red flashes and a Three (3) second pause| One (1) -Zone 1 or 2 error flash and a Three (3) second pause| Thermocouple error| Open Thermocouple or Control Board failure| Thermocouple/ Control Board| Check thermocouple and control board operation. Replace failed part.
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Four (4) -Red flashes and a Three (3) second pause| One (1) -Zone 1 or 2 error flash and a Three (3) second pause| Low Fan Speed error| Fan or Control Board failure| Fan/Control Board| Check fan and control board operation. Replace failed part.
Four (4)- Red flashes and a Three (3) second pause| Two (2) -Zone 1 or 2 error flash and a Three (3) second pause| High Fan Speed error| Fan or Control Board failure| Fan/Control Board| Check fan and control board operation. Replace failed part.
Five (5)- Red flashes and a Three (3) second pause| N/A| Control Board to Control Board Communication error| DC Cable or Control Board failure| DC Cable/ Control Board| Check DC cable between IO boards and control board operation. Replace failed part.
Continuous fast pulses of green| N/A| Successful menu/software update| N/A| N/A| N/A
Six (6)- Red flashes and a Three (3) second pause| N/A| Incorrect wire connection issue.| Heater or thermocouple connected to incorrect zone connection.| N/A| Check wiring diagram for correct connections.
Seven (7)- Red flashes and a Three (3) second pause| N/A| Compartment temperature is too high.| Air filter intake may be blocked (if applicable).| Air Filter (if applicable)| Ensure the air intake is not blocked. Ensure the cabinet is not placed up against a wall or fryer blocking the air intake.

Measuring Air Temperature
To determine if the CrispyMax is delivering the correct air temperature, use a thermocouple to measure the air temperature.

1. Remove the holding pan to access the air grill.
2. Tape a thermocouple over the air grill as shown, ensuring that the thermocouple does not touch the grill. The thermocouple should be centered in the center of the grill, in front of the third fin down.
3. Let the holding station temperature stabilize and take reading.
4. If the temperature is 270F (132C) or higher, the unit is working properly. If the temperature is lower than 270F (132C), there may be an issue. There may be a slightly different temperature depending on product menu setpoint temperatures.

Updating Software

1. Connect the power cord on the unit to the wall.
2. Ensure the power switch on the front of the unit is in the OFF position (Indicator LED is off).
3. Insert the USB drive into the USB slot with the software file.
4. The indicator LED will alternate between green, amber and red, indicating the software update is in progress.
5. The indicator LED will display (see Note 1 below), when successful.
6. If the file was invalid or corrupt, the indicator LED will display continuous fast red pulses.
7. Remove the USB and switch on the power switch.

Updating Menus

1. Connect the power cord on the unit to the wall.
2. Ensure the power switch on the front of the unit is in the OFF position (Indicator LED is off).
3. Insert the USB drive into the USB slot with the menu file.
4. The indicator LED will display (see Note 1 below), when successful.
5. If the file was invalid or corrupt, the indicator LED will display continuous fast red pulses.
6. Remove the USB and switch on the power switch.

Note 1:
The indicator LED will display: – Fast continuous green pulses.

Wiring Diagrams

CrispyMax Wiring Non-CE

CrispyMax Wiring with voltages

CrispyMax Wiring CE

Welbilt offers fully-integrated kitchen systems. Welbilt’s portfolio of award- winning brands includes Cleveland™, Convotherm®, Crystal Tips®, Dean®, Delfield®, Fabristeel®, Frymaster®, Garland®, Inducs®, Koldtech®, Kolpak®, Lincoln®, McCann’s™, Merco®, Merrychef®, Multiplex®, RDI®, SerVend™, SunFire®, U.S. Range™ and WMaxx™. These product brands are supported by these service brands: FitKitchen®, our fully-integrated kitchen systems brand, and KitchenConnect®, our cloud-based digital platform brand.
Bringing innovation to the table · welbilt.com
©2023 Welbilt Inc. except where explicitly stated otherwise. All rights reserved. Continuing product improvement may necessitate change of specifications without notice.
Part Number: MER_SM_8197929 05/2023

MERCO
8700 LINE AVENUE, SHREVEPORT, LA 71106-6800
Serving Quality on Demand
MERCO SALES: 800.221.4583
MERCO SERVICE: 877.392.7770
WWW.MERCOPRODUCTS.COM

Documents / Resources

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8197929, 8197929 Crisp and Ready Serving Station, Crisp and Ready Serving Station, Ready Serving Station, Serving Station, Station
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References

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