SERVICE & PARTS MANUAL 1024, 1036, 1048 CHEESEMELTER MODELS 1024C 1024W 1024P 1036C 1036W 1036P 1048C Canadian 1048W Canadian 1048P Canadian ML-103833 ML-103834 ML-103835 ML-103836 ML-103837 ML-103838 ML-103839 ML-126600 ML-103840 ML-126602 ML-103841 ML-126601 Model 1024 VULCAN-HART COMPANY, P.O. BOX FORM 31087 (June 2000) (Formerly 991007A) 696, LOUISVILLE, –1– KY 40201-0696, TEL. (502) 778-2791 www.vulcanhart.com PARTS REPLACEMENT WARNING: DISCONNECT ELECTRICAL POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH TO INDICATE YOU ARE WORKING ON THE CIRCUIT BEFORE SERVICING. HEATER (Fig. 1) 1. Push one end of the heater into one socket as far as it will go. 2. Swing the other end of heater up until it lines up with the opposite socket. 3. Release heater and it will snap into place. 4. Grasp the heater and move it back and forth to ensure that it is centered correctly. 5. Rotate the heater clockwise, then counterclockwise, to ensure that it is seated correctly. PL-53526-E Fig. 1 COOLING FANS 1. Remove the access panel on the left side of the cheesemelter. 2. Unscrew the four mounting screws. 3. Disconnect the fan leads and lift out the fan. 4. Install new fan. • Make sure that all wires are enclosed by the nylon wire clamps so that none of the wires can reach the fan blades. The cooling fan should blow air into the control compartment. An arrow on the fan housing indicates the direction of air flow. –2– COMPONENT REPLACEMENT 1. Remove the access panel on the left side. 2. Remove all screws holding down the cover. 3. Lift cover straight up. Replacement of the voltage regulator, actuating switch, main terminal block, or the contactor (1048 only) will require removing the component mounting plate. 1. Disconnect the wires from the “on” pilot light and the switches. 2. Tag or mark the wires to ensure correct replacement. 3. Remove the two mounting screws. • One is located at the bottom left of the voltage regulator. • The other is located under the lower part of the cooling fan. This screw can be reached through the blades of the fan. 4. Remove the component mounting plate and replace the component. Make sure that the screw that operates the actuating switch is above the switch lever. –3– COMPONENT LOCATION DRAWING SOCKETS CONTACTOR (1048) VOLTAGE REGULATOR PILOT LIGHT COMPONENT MOUNTING PLATE TERMINAL BLOCK NYLON LOOP COOLING FAN SWITCH ACTUATING SWITCH GROUND STUD PL-53527 COMPONENT LOCATION (VIEW OF LEFT SIDE WITH COVER REMOVED) –4– TROUBLESHOOTING (See component location drawing on page 4.) WARNING: DISCONNECT POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH TO INDICATE YOU ARE WORKING ON THE CIRCUIT BEFORE SERVICING. IF THE UNIT BLOWS A FUSE OR TRIPS A CIRCUIT BREAKER 1. Check the capacity of the circuit. 2. Short circuits may be accompanied by sputtering sounds or sparks. IF THE HEATERS DO NOT LIGHT 1. If the pilot light does not come on, and the cooling fan does not run, check for a blown fuse or an open circuit breaker. 2. Check for failure of the main switch. 3. On the 1048, check for contactor failure. 4. Check for a loose wiring connection. 5. If the pilot light is lit, and the cooling fan is running, but the heaters do not light, check for loose wiring connections. When the cheesemelter is operating in standby with no product on the rack, the heaters may not glow, but will still emit some heat. 6. If one heater is lit, but the other is not, a burnout or a loose connection is the probable cause. Also, check that the heater is properly seated in its socket. IF THE COOLING FAN DOES NOT RUN 1. If the pilot light is not lit, and the heaters do not light, check for a blown fuse or open circuit breaker. 2. If the pilot light is lit and the heaters function, the probable cause is a loose connection. IF THE HEATERS DO NOT COME UP TO FULL HEAT WHEN THE PRODUCT IS PLACED ON THE RACK 1. Be sure that the product is on the front half of the rack. The rack is balanced to trip the actuating switch, but the weight must be on the front half of the rack to ensure that it does so. 2. Check that the rack is at the same level on both sides and is correctly inserted. 3. If the rack operates freely, the failure of the actuating switch is the probable cause. –5– ELECTRICAL SCHEMATIC 1024 & 1036 HEATERS VOLTAGE REGULATOR ACTUATING SWITCH FAN PILOT LIGHT MAIN SWITCH PL-53528 TERMINAL BLOCK GROUND LUG –6– ELECTRICAL SCHEMATIC 1048 LEFT SIDE HEATERS RIGHT SIDE HEATERS VOLTAGE REGULATOR ACTUATING SWITCH RIGHT PILOT LIGHT LEFT PILOT LIGHT LEFT SWITCH RIGHT SWITCH FAN MAIN PILOT LIGHT CONTACTOR 1048 SCHEMATIC MAIN SWITCH TERMINAL BLOCK GROUND STUD PL-53529 –7– ITEM NO. DESCRIPTION PART NUMBER 1024 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 37 38 39 40 Heater (208V.) Heater (240V.) Heater Socket Pilot Light Main Switch Left/Right Heat Switch Contactor Terminal Block Voltage Regulator Cooling Fan Fan Guard Nylon Wire Clamp Actuating Switch Counter Leg Wiring Hole Plug Rack Outside Cover Mounting Screws Heat Shield/Deflector Wire Guard Ceramic Wire Nuts Back Stop Outer Wrap Access/Control Box Cover Access Panel Screws TCP Panel Cover LH Pivot (2 Position) RH Pivot (2 Position) LH Pivot (4 Position) RH Pivot (4 Position) Switch - Slide (2 Slots) Switch - Slide (4 Slots) Slide Bracket Nut Screw Screw Washer Lockwasher Lockwasher Legs FORM 31087 (June 2000) 825536 825538 825098 825100 825100-10 — — 825126-40 825128-90 825100-80 825100-50 815090-2 825126-30 825172-50 825168-10 825168-20 SC-066-21 825083 851588 FE-009-34 825072 825085 825195 SC-053-38 — 825196 825199 825071 825071-10 825198 825073 825073 NS-011-018 SC-119-065 SC-119-023 WS-002-025 WL-014-007 WL-006-007 804405 –8– 1036 825531 825532 825098 825100 825100-10 — — 825126-40 825128-90 825100-80 825100-50 815090-2 825126-30 825172-50 825168-10 825172-10 SC-066-21 825083-10 850016 FE-009-34 825072 825085-10 825195 SC-053-38 825191 — — 825071 825071-10 825198 825073 825073 NS-011-018 SC-119-065 SC119-023 WS-002-025 WL-014-007 WL-006-007 804405 1048 825300 (1050w) 825301 (1050w) 825098 825100 825100-10 825100-10 825126-10 825126-40 825128-90 825100-80 825100-50 815090-2 825150-90 825172-50 825168-10 825168-30 SC-066-20 825083 (2) 850329 FE-009-34 850072 825085-20 825195 SC-053-38 — — — 825071 825071-10 825198 825073 825073 NS-011-018 SC-119-065 SC-119-023 WS-002-025 WL-014-007 WL-006-007 804405 PRINTED IN U.S.A.