Frymaster Toaster CT16 Series User Manual

Frymaster, a member of the Commercial Food Equipment Service Association, recommends  
using CFESA Certified Technicians.  
JANUARY 2004  
24-Hour Service Hotline 1-800-551-8633  
* 8 1 9 5 9 9 3 *  
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NOTICE  
IF, DURING THE WARRANTY PERIOD, THE CUSTOMER USES A PART FOR THIS ENODIS  
EQUIPMENT OTHER THAN AN UNMODIFIED NEW OR RECYCLED PART PURCHASED  
DIRECTLY FROM FRYMASTER/DEAN, OR ANY OF ITS AUTHORIZED SERVICE CENTERS,  
AND/OR THE PART BEING USED IS MODIFIED FROM ITS ORIGINAL CONFIGURATION, THE  
WARRANTY WILL BE VOID. FURTHER, FRYMASTER/DEAN AND ITS AFFILIATES WILL NOT BE  
LIABLE FOR ANY CLAIMS, DAMAGES OR EXPENSES INCURRED BY THE CUSTOMER WHICH  
ARISE DIRECTLY OR INDIRECTLY, IN WHOLE OR IN PART, DUE TO THE INSTALLATION OF  
ANY MODIFIED PART AND/OR PART RECEIVED FROM AN UNAUTHORIZED SERVICE CENTER.  
NOTICE  
This appliance is intended for professional use only and is to be operated by qualified  
personnel only. A Frymaster/DEAN Factory Authorized Service Center (FASC) or other qualified  
professional should perform installation, maintenance, and repairs. Installation, maintenance,  
or repairs by unqualified personnel may void the manufacturer’s warranty.  
NOTICE  
This equipment must be installed in accordance with the appropriate national and local codes of  
the country and/or region in which the appliance is installed.  
NOTICE TO U.S. CUSTOMERS  
This device complies with Part 15 of the FCC rules. Operation is subject to the following two  
conditions: 1) This device may not cause harmful interference, and 2) This device must accept  
any interference received, including interference that may cause undesired operation. While  
this device is a verified Class A device, it has been shown to meet the Class B limits.  
NOTICE TO CANADIAN CUSTOMERS  
This digital apparatus does not exceed the Class A or B limits for radio noise emissions as set  
out by the ICES-003 standard of the Canadian Department of Communications.  
Cet appareil numerique n’emet pas de bruits radioelectriques depassany les limites de classe A  
et B prescrites dans la norme NMB-003 edictee par le Ministre des Communcations du Canada.  
DANGER  
Improper installation, adjustment, maintenance or service, and unauthorized alterations or  
modifications can cause property damage, injury, or death. Read the installation, operating,  
and service instructions thoroughly before installing, operating or servicing this equipment.  
Do not operate the CT16 Toaster unless it has been properly installed and checked.  
Do not operate the CT16 Toaster unless all covers and access panels are in place and properly  
secured.  
Do not attempt to repair or replace any component of the CT16 Toaster unless all power to the  
unit has been disconnected.  
Use caution when setting up, operating, or cleaning the CT16 Toaster to avoid contact with  
heated surfaces.  
DANGER  
Do not store or use gasoline or other flammable liquids or vapors in the vicinity of this or any  
other appliance.  
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CT16 SERIES TOASTER  
SERVICE AND PARTS MANUAL  
CHAPTER 1: SERVICE PROCEDURES  
Upper  
Compression  
Adjustment  
Knobs  
Bun Guide for Heel  
and Crown Slots  
LED  
DISPLAY  
REDY  
RAISE  
SETPOINT  
BUTTON  
LOWER  
SETPOINT  
BUTTON  
DISPLAY  
TEMPERATURE  
BUTTON  
ON/OFF  
BUTTON  
Lower  
Compression  
Adjustment  
Knobs  
Heated Holding Tray  
1.1 CT16 Toaster Functional Description  
The CT16 Toaster is designed to produce fresh, uniformly toasted buns on an "as needed” basis. The  
countertop-mounted unit consists of a cabinet, a computer, a heating element and a pair of conveyor  
assemblies.  
When the unit is turned on, an electrical heating element (called a platen) is energized. The platen  
heats up to a programmed temperature referred to as the setpoint. At the same time, both conveyor  
assemblies are activated. When a bun is placed into one of the slots at the top of the cabinet, the  
conveyor belts gently carry it through the unit, with the cut face of the bun passing over the heated  
platen. As the bun passes over the platen, it is toasted. At the end of the process, the bun is deposited  
onto a holding tray. The computer allows the operator to adjust the setpoint to obtain desired toasting  
characteristics. Compression adjustment knobs also allow the operator to adjust the compression of  
heels and crowns as they pass through the toaster.  
1.2 Power Requirements  
ALL ELECTRICALLY OPERATED APPLIANCES MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES, OR  
IN THE ABSENCE OF LOCAL CODES, WITH THE NATIONAL ELECTRICAL CODE (ANSI/NFPA NO. 70-1990) OR THE  
CORRESPONDING NATIONAL CODE OF THE COUNTRY IN WHICH INSTALLED.  
THIS APPLIANCE IS EQUIPPED WITH A GROUNDING PLUG FOR YOUR PROTECTION AGAINST SHOCK HAZARD AND MUST BE  
PLUGGED INTO A PROPERLY GROUNDED RECEPTACLE. DO NOT CUT OR REMOVE THE GROUNDING PRONG FROM THIS PLUG!  
Voltage: 200VAC, 208VAC, or 240VAC, depending on model ordered  
Frequency: 60 Hz (non-CE )or 50 Hz (CE and Australian models)  
Phase: Single  
Service: 20 Amp  
1-1  
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1.3 Replacing Components  
Accessing the Electronics  
1. Pull the bun compression knobs off their shafts.  
2. Remove the screws around the edge of the component housing cover and remove the cover.  
Accessing the Drive Motor and Auxiliary Transformer  
Carefully lay the unit on its back and remove the seven screws that secure the bottom cover in place.  
Removing the Conveyor Assemblies  
1. Turn off and unplug the unit.  
2. Remove the bun feeder then remove the cover by lifting it straight up until it is clear of its hinge  
pins.  
3. Rotate the bun compression knobs to positions 5 and E.  
4. Press down on the top roller(s) of the conveyor assembly to be removed to lock it (them) in the  
down position.  
5. Rotate the tray stabilizer latch upward, then remove the belt(s). Return the tray stabilizer latch to  
the latched position.  
6. Pull the bun compression knobs from their shafts.  
7. Remove the screws around the edge of the component housing cover and remove the cover.  
8. Remove the diagonal brace.  
9. Release the tension on the drive belt by pressing down on the belt tensioner arm and remove the  
belt from the pulleys.  
10. To remove the dual-belt conveyor assembly:  
(See illustration on following page.)  
a. Loosen the setscrew in the forward-most drive pulley and remove the pulley.  
b. Remove the cartridge heater, marking the leads to facilitate reconnection.  
c. Remove the four hex-head screws and two flange nuts that secure the conveyor assembly to the  
component housing from the inside.  
d. Rotate the tray stabilizer latch upward and, while supporting the conveyor assembly, remove the  
two hex-head screws securing the top of the conveyor assembly from the outside (conveyor  
side) of the component housing and carefully pull the conveyor assembly away from the housing.  
e. Reinstall the conveyor assembly by reversing the steps performed, being sure to reattach the  
ground wire with the top hex head screw.  
1-2  
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Step 10d - Remove last two screws  
and pull conveyor away from housing.  
Step 10c - Remove  
these four hex head  
screws and two nuts.  
Step 10b - Remove  
cartridge heater.  
Step 10a - Remove drive pulley.  
11. To remove the toasting conveyor assembly:  
(See illustration on following page.)  
a. Detach the platen and probe wiring from the relay, high-limit, and 9-pin connector.  
b. Loosen the setscrew in the second drive pulley from the front and remove the pulley.  
c. Remove the five flange nuts that secure the idler assembly to the housing and remove the idler  
assembly.  
d. Remove the two hex head screws shown in Step 11d of the illustration on the following page.  
1-3  
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e. Rotate the tray stabilizer latch upward and, while supporting the conveyor assembly, remove the  
hex-head screw securing the top of the assembly from the outside (conveyor side) of the  
component housing and carefully pull the assembly away from the housing.  
Step 11e - Remove the last screw and pull  
the conveyor away from the housing.  
Step 11c - Remove  
these five flange nuts  
and the idler assembly.  
Step 11d - Remove these  
two hex head screws.  
Step 11b - Remove the drive pulley.  
f. Reinstall the conveyor assembly by reversing the steps performed, being sure to reattach the  
two ground wires with the lower of the two hex head screws removed in Step 11d.  
Replacing the High-Limit Thermostat or Heater Probe  
(See illustration on following page.)  
1. Turn off and unplug the unit, and remove toasting conveyor in accordance with the instructions on  
Pages 18-19.  
2. To replace the high-limit thermostat, remove the platen tray brace to expose the thermostat and  
remove the screws securing it in place.  
3. To replace the heater probe, remove the plug over the probe to expose the component. Remove  
the screw securing the probe retainer and remove the probe.  
1-4  
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Heater Probe  
NOTE: Probe  
and high limit  
wires must be  
routed through  
this bushing as  
shown by large  
arrow.  
High Limit  
Plug  
Platen Tray Brace  
4. Replace the failed component, being sure to route the component wires through the bushing as  
shown in the illustration above. Reassemble by reversing the steps performed and reconnect the  
wiring in accordance with the wiring diagram on the inside of the component housing cover.  
Replacing the Drive Motor or Auxiliary Transformer  
(See illustration on following page.)  
1. Turn off and unplug the unit.  
2. Pull the bun compression knobs from their shafts.  
3. Remove the screws around the edge of the component housing cover.  
4. Disconnect the failed component’s wiring, then carefully lay the unit on its back.  
5. Remove the screws that secure the bottom cover in place and remove the cover. NOTE: The two  
cap screws that pass through the bottom of the component housing also hold the belt tensioner  
assembly in place.  
6. To replace the drive motor, remove the screws that secure the diagonal brace to the component  
housing. Remove the drive belt. Loosen the setscrew securing the motor pulley to the motor shaft  
and remove the pulley. Hold the replacement motor next to the failed motor and transfer the wiring  
connections to the replacement. Remove the four screws that secure the motor to the cabinet and  
install the replacement.  
1-5  
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7. To replace the auxiliary transformer (present only in 200V and 208V units), hold the replacement  
next to the failed transformer and, one at a time, disconnect the wires from the failed transformer  
and connect them to the replacement. When all wiring has been transferred, remove the screws  
and nuts that secure the transformer to the back wall of the motor compartment and install the  
replacement.  
Short screws  
8. Reverse the steps performed to reassemble unit.  
Replacing the Dual Belt Conveyor Cartridge Heater  
1. Turn off and unplug the unit.  
2. Pull the bun compression knobs off their shafts.  
3. Remove the screws in the edge of the component housing cover.  
4. Disconnect the heater leads. Remove the hex-head screws securing the heater in place and  
remove the heater (see illustration on Page 1-6).  
5. Reverse steps 1-4 to reassemble the unit.  
Replacing the Transformer or Relays  
1. Turn off and unplug the unit.  
2. Pull the bun compression knobs from their shafts.  
3. Remove the screws in the edge of the component housing cover.  
4. Hold the replacement component next to the component to be replaced and, one at a time,  
disconnect the wires from the failed component and connect them to the replacement component.  
5. Remove the screws and/or nuts securing the failed component to the component housing and  
install the replacement.  
6. Reverse steps 1-3 to reassemble the unit.  
1-6  
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1.4 Technician Troubleshooting  
PROBLEM  
PROBABLE CAUSES  
CORRECTIVE ACTION  
A. Check for line voltage on the primary  
(line) side of transformer and 12VAC on  
secondary (load) side of transformer. If  
line voltage is present but secondary  
voltage is not 12VAC, the transformer has  
failed.  
A. Failed transformer.  
B. Failed computer.  
B. Check continuity between right terminal  
of secondary (load) side of transformer  
and Pin 9 of the 9-pin connector when the  
cover interlock switch is closed. If  
Display remains blank  
when unit turned on.  
resistance is zero, replace the computer.  
C. Check continuity between switch  
terminals when the switch is closed.  
If resistance is infinite, replace switch. If  
resistance is zero, replace high limit.  
C. Failed cover interlock switch or failed  
high limit.  
A. Failed motor.  
A. If platen is heating, replace motor.  
B. Check for 12VDC on Pins 6 & 7 of  
computer. If present and wiring is intact,  
replace latch relay. If not present, replace  
computer.  
Computer display is on, but  
motor is not running  
B. Broken/loose wire between computer and  
latch relay or failed latch relay.  
Motor is running at wrong  
speed (i.e. average time for  
three individual buns to  
pass through toaster is  
NOT between 15 and 18  
seconds).  
A. Check data plate for voltage rating, and  
verify that power supply and toaster  
match.  
A. Toaster improperly configured for power  
supply.  
A. Verify that the power supply is 20 amp  
single-phase 200, 208 or 240VAC  
(depending upon model).  
A. Improper power-supply.  
B. Failed temperature probe.  
B. Use a temperature-measuring device to  
determine actual platen temperature. If  
measured temperature is within 10 degrees  
of the temperature displayed on the  
computer and the probe resistance at pins  
3 and 5 of the 9-pin connector does not  
correspond to the appropriate value in the  
probe resistance chart on Pages 24 and 25,  
replace the probe.  
Platen heats, but unit does  
not reach setpoint.  
C. Use a temperature-measuring device to  
determine actual platen temperature. If  
measured temperature is within 10 degrees  
of the temperature displayed on the  
C. Failed computer.  
computer and probe resistance at pins 3  
and 5 of the 9-pin connector corresponds  
to the value in the probe resistance chart  
on Pages 24 and 25, replace the computer.  
1-7  
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PROBLEM  
PROBABLE CAUSES  
CORRECTIVE ACTION  
A. Check for 12VDC on computer pins 6 &  
7. If NOT present AND motor is running,  
replace computer. Check for 5VDC on  
terminals 3 & 4 of main heater relay and  
pins 1 and 6 of computer. If NOT present  
at either point AND motor is running,  
replace computer.  
A. Failed computer.  
B. Check for 12VDC on computer pins 6 &  
7. If present and wiring is intact, replace  
latch relay.  
B. Broken/loose wire between computer and  
latch relay, or failed latch relay.  
C. Determine temperature of platen then  
measure main heater probe resistance at  
pins 3 & 5 of 9-pin connector. If the  
probe resistance is NOT approximately  
equal to the corresponding resistance in  
the chart on Pages 24 and 25, replace the  
probe.  
Platen does not heat, but  
computer display is on.  
C. Failed main heater probe.  
D. Check for 5VDC on terminals 3 & 4 of  
main heater relay AND on computer pins  
1 & 6. If present on pins 1 & 6, but NOT  
on terminals 3 & 4, and wiring is intact,  
replace the main heater relay.  
D. Broken/loose wire between computer and  
main heater relay, or failed main heater  
relay.  
E. Check for 5VDC on terminals 3 & 4 of  
main heater relay and for line voltage on  
terminal 2 of main heater relay and  
terminal 4 of latch relay. If expected  
voltage is present at all three points,  
replace the platen.  
E. Failed platen.  
Probe Resistance Chart  
For use with CT16 Series toasters manufactured with Minco Thermistor probes only.  
F
60  
65  
70  
75  
80  
85  
90  
OHMS  
1059  
1070  
1080  
1091  
1101  
1112  
1122  
1133  
1143  
1154  
1164  
1174  
1185  
1195  
1204  
1216  
1226  
1237  
1247  
1258  
C
F
OHMS  
1268  
1278  
1289  
1299  
1309  
1320  
1330  
1340  
1350  
1361  
1371  
1381  
1391  
1402  
1412  
1422  
1432  
1442  
1453  
1463  
C
F
OHMS  
1473  
1483  
1493  
1503  
1514  
1524  
1534  
1544  
1554  
1564  
1574  
1584  
1594  
1604  
1614  
1624  
1634  
1644  
1654  
1664  
C
F
OHMS  
1674  
1684  
1694  
1704  
1714  
1724  
1734  
1744  
1754  
1764  
1774  
1783  
1793  
1803  
1813  
1823  
1833  
1843  
1852  
1862  
C
F
OHMS  
1872  
1882  
1892  
1901