MANUFACTURING NUMBERS: 9210114 9210118 9210109 VERTICAL CONTACT TOASTER AN Model VCT-2000 I T A T IO L IS N S T ED C CM L IS T ED US P/N 1010832 Rev. D 02/13 Owner ’s Manual VERTICAL CONTACT TOASTER TABLE OF CONTENTS Table of Contents.....................................................2 Owner Information....................................................2 General.....................................................................2 Warranty Information................................................2 Service/Technical Assistance...................................3 Important...................................................................3 Important safety information...................................4 Specifications...........................................................5 Electrical Ratings & Plug Configurations.................5 Dimensions...............................................................5 Installation.................................................................6 Unpacking................................................................6 Equipment Setup......................................................6 Assembling the Unit.................................................6 Operation...................................................................8 Operating Instructions..............................................8 Temperature Adjustments........................................8 Hi-Limit Reset Button.............................................10 Fault Codes............................................................10 Maintenance............................................................11 Daily.......................................................................11 Replacing the Black and Silver Release Sheet (Every 4–6 Weeks).................................................12 Replacing the Belt Wraps (Every 3–6 Months)................................................12 Checking the Conveyor Belt Chains (Every 3–6 Months)................................................13 Checking the Roller Tensioners (every 3–6 months)................................................14 Troubleshooting.....................................................15 Wiring Diagram.......................................................19 Replacement Parts.................................................21 NOTES.....................................................................27 Limited Warranty......................................................28 OWNER INFORMATION General Warranty Information The Vertical Contact Toaster Model VCT-2000 is designed for contact toasting of buns. The toaster design allows the operator to place buns on both sides of the heated platen at the same time. Buns are placed into the top of the toaster and uniform, golden brown, warm buns are then retrieved from the base of the toaster. Please read the full text of the Limited Warranty in this manual. This manual provides the safety, installation, and operating procedures for the Vertical Contact Toaster Model VCT-2000. We recommend that all information contained in this manual be read prior to installing and operating the unit. The warranty does NOT extend to: If the unit arrives damaged, contact the carrier immediately and file a damage claim with them. Save all packing materials when filing a claim. Freight damage claims are the responsibility of the purchaser and are NOT covered under warranty. Your Vertical Contact Toaster Model VCT-2000 is manufactured from the finest materials available and assembled to Roundup’s strict quality standards. This unit has been tested at the factory to ensure dependable trouble-free operation. • Damages caused in shipment or damage as result of improper use. • Installation of electrical service. • Normal maintenance as outlined in this manual. • Malfunction resulting from improper maintenance. • Damage caused by abuse or careless handling. • Damage from moisture into electrical components . • Damage from tampering with, removal of, or changing any preset control or safety device. IMPORTANT! Keep these instructions for future reference. If the unit changes ownership, be sure this manual accompanies the equipment. 2 P/N 1010832 Rev. E 02/13 VERTICAL CONTACT TOASTER OWNER INFORMATION (continued) Service/Technical Assistance Refer to the service agency directory included with your unit. If you experience any problems with the installation or operation of your unit, contact your local Roundup Authorized Service Agency. Authorized Service Agency Name: Fill in the information below and have it handy when calling your Authorized Service Agency for assistance. The serial number is on the specification plate located on the rear of the unit. Phone No.: Address: Use only genuine Roundup replacement parts in this unit. Use of replacement parts other than those supplied by the manufacturer will void the warranty. Your Authorized Service Agency has been factory trained and has a complete supply of parts for this toaster. Purchased From: Date of Purchase: Model No.: Serial No.: You may also contact the factory at 1-877-392-7854 (toll Free in the U.S.) or 630-784-1000 if you have trouble locating your nearest Authorized Service Agency. Mfg. No.: IMPORTANT A.J. Antunes & Co. reserves the right to change specifications and product design without notice. Such revisions do NOT entitle the buyer to corresponding changes, improvements, additions, or replacements for previously purchased equipment. CAUTION All electrical connections must be in accordance with local electrical codes and any other applicable codes. WARNING ELECTRICAL SHOCK HAZARD. FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS MANUAL COULD RESULT IN SERIOUS INJURY OR DEATH. • Electrical ground is required on this appliance. • Do NOT modify the power supply cord plug. If it does not fit the outlet, have a proper outlet installed by a qualified electrician. • Do NOT use an extension cord with this appliance. • Check with a qualified electrician if you are unsure if the appliance is properly grounded. P/N 1010832 Rev. E 02/13 3 VERTICAL CONTACT TOASTER IMPORTANT SAFETY INFORMATION • Bread may burn. Therefore toasters must not be used near or below curtains or other combustible walls and materials. Failure to maintain safe operating distances may cause discoloration or combustion. • When installing conveyor belt wrap, be careful not to wrap it over the upper and lower support rods or permanent damage to belt will occur. Make sure belt wrap is positioned UNDER the upper and lower support rods. • Do NOT operate this equipment if it has a damaged cord or plug, if it is not working properly, or if it has been damaged or dropped. • Make sure both ends of belt wrap are aligned evenly before installing belt wrap pin. • This equipment should be serviced by qualified personnel only. Contact the nearest Authorized Service Agency for adjustment or repair. • Failure to use release sheets may result in damage to the equipment and loss of warranty coverage. • Do NOT clean this appliance with a water jet. • If power cord is damaged, it must be replaced by the manufacturer or its service agent, or a similarly qualified person. • All electrical connections must be in accordance with local electrical codes and any other applicable codes. • WARNING, ELECTRICAL SHOCK HAZARD. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH. In addition to the warnings and cautions in this manual, use the following guidelines for safe operation of the unit. • Read all instructions before using equipment. • For your safety, the equipment is furnished with a properly grounded cord connector. Do NOT attempt to defeat the grounded connector. • Install or locate the equipment only for its intended use as described in this manual. Do NOT use corrosive chemicals in this equipment. • Do NOT block or cover any openings on the unit. • Do NOT immerse cord or plug in water. • Keep cord away from heated surfaces. • Do NOT allow cord to hang over edge of table or counter. The following warnings and cautions appear throughout this manual and should be carefully observed. -Electrical ground is required on this appliance. • Turn the power off, unplug the power cord, and allow unit to cool down before performing any service or maintenance. - Do NOT modify the power cord plug. If it does not fit the outlet, have a proper outlet installed by a qualified electrician. • The toaster should be grounded according to local electrical codes to prevent the possibility of electrical shock. It requires a grounded receptacle with separate electrical lines protected by fuses or a circuit breaker of the proper rating. - Do NOT use an extension cord with this appliance. - Check with a qualified electrician if you are unsure if the unit is properly grounded. 4 P/N 1010832 Rev. E 02/13 VERTICAL CONTACT TOASTER SPECIFICATIONS Electrical Ratings & Plug Configurations Model & Mfg. Number VCT-2000 9210114/ 9210109 (9 RPM Unit) VCT-2000 9210118 (3 RPM Unit) Volts 208 Watts 3291 Amps Hertz Plug Description 50/60 NEMA 6-20P 20 Amp., 250 VAC., NonLocking 15.8 Configuration Dimensions 15-1/4” (387.35 mm) 20-5/16" (515.87 mm) 29-3/16” (741.36 mm) 9-3/4” (247.65 mm) For Mfg. No. 9210109 10 - 3/4" 273.05 20-5/16" 515.87mm 15-1/4" (387.35mm) 23-7/32" 589.53mm 22-11/16" 576.07mm 9-3/4" (247.65mm) For Mfg. No. 9210114 and 9210118 P/N 1010832 Rev. E 02/13 5 VERTICAL CONTACT TOASTER INSTALLATION Unpacking Assembling the Unit 1. Remove unit and all packing materials from shipping carton. NOTE: The factory has pre-installed a Release Sheet over the Platen (Figure 1). Verify that it is properly in place before proceeding. 2. Open the included large box. It should contain the following: • Bun Chute (Figure 1) • Butter Wheel and Pan (Figure 1) • Two Release Sheets (Figure 1) • Owner’s Manual • Maintenance Card • Authorized Service Agency Directory CAUTION Failure to use Release Sheets may result in damage to the unit and loss of warranty coverage. 1. Remove Bun Chute from the box and install (Figure 1). 2. Remove Butter Wheel and Pan from box. Install the Pan over the front edge of the Heat Shield and place the Butter Roller in Pan and engage in to gear case (Figure 1). 3. Remove all shipping tape and protective coverings from the unit and parts. NOTE: If any parts are missing or damaged, contact Antunes Technical Service IMMEDIATELY at 1-877-392-7854 (toll free in the U.S.) or 630-784-1000. IMPORTANT: Make sure Heat Shield assembly is activating the Conveyor Interlock Switch (Figure 1). The conveyors will not rotate unless the Heat Shield is in place and Conveyor Interlock Switch is activated. Equipment Setup Before placing the toaster into service, pay attention to the following guidelines: • Make sure power to the unit is off and the toaster is at room temperature. • Do NOT block or cover any openings on the unit. • Do NOT immerse cord or plug in water. • Keep cord away from heated surfaces. • Do NOT allow cord to hang over edge of table or counter. • Connect the unit to the proper power supply. Refer to the specification plate for the proper voltage. CAUTION Bread may burn. Therefore toasters must not be used near or below curtains or other combustible walls and materials. Failure to maintain safe operating distances may cause discoloration or combustion. 6 P/N 1010832 Rev. E 02/13 VERTICAL CONTACT TOASTER INSTALLATION (continued) Butter Wheel Pan Heat Shield Release Sheet Retainer Clips Bun Chute Assembly connected over the bottom rear support rod Release Sheet Platen Rear Conveyor Belt Chain Rear Cleated Belt Wrap Conveyor Safety Interlock Switch Front Conveyor Belt Chain Front Cleated Belt Wrap Rear Conveyor Cover Assembly (with Roller Tensioner) Roller Tensioner Front Conveyor Cover Assembly Bun Chute Figure 1. VCT-2000 Toaster P/N 1010832 Rev. E 02/13 7 VERTICAL CONTACT TOASTER OPERATION Operating Instructions Bun Thickness Adjustment Control (See Figure 3) 1. Set the Bun Thickness Adjustment Controls (Figure 3) to desired setting. NOTE: Recommended settings are #2 for heel and #6 for crown. THICKNESS THICKNESS 6 3 2 5 1 4 2. Turn the power on and allow the toaster to warmup for 30 minutes before proceeding. 4 1 5 6 NOTE: The Temperature Display (Figure 2) will flash “LO” until the toaster reaches its preset operating temperature. When the toaster approaches the preset temperature of 600°F (315°C), “USE” appears in the Temperature Display and the unit is ready to toast buns. If “USE” does not appear in the window after warmup period of approximately 30 minutes, contact your Authorized Service Agency. Power Cord 1 = 1/2"(12.7mm) 2 = 5/8"(15.9mm) 3 = 11/16"(17.5mm) 4 = 3/4"(19.1mm) 5 = 13/16"(20.6mm) 6 = 7/8"(22.2mm) 2 3 Butter Wheel and Pan Hi-Limit Reset 3. Slide buns across the rotating Butter Wheel with the cut face down and drop buns into the Bun Feeder. The cut sides of heel and crown must face each other and slide against the Release Sheet. Bun Landing Area Temperature Controls & Temperature Display Power Switch Figure 2. VCT-2000 Toaster 4. Toasted buns will drop into the Bun Landing Area (Figure 2) in approximately 15 seconds. THICKNESS 5. Test at least 4 buns before putting the toaster into service. THICKNESS 6 3 6. Turn the power off when finished toasting for the day and proceed with the daily cleaning as outlined in the Maintenance section of this manual. 2 5 1 4 Temperature Adjustments 4 1 5 The VCT-2000 uses a Platen Heater and two Auxiliary Air Heaters. The Platen Heater consists of a heating element built into the Platen to toast the cut side of the bun. The two Auxiliary Air Heaters assist in providing additional heat to the buns. The first Auxiliary Air Heater is located within the conveyor in the front of the toaster. The second Auxiliary Air Heater is located within the conveyor at the rear of the unit. 6 1 = 1/2"(12.7mm) 2 = 5/8"(15.9mm) 3 = 11/16"(17.5mm) 4 = 3/4"(19.1mm) 5 = 13/16"(20.6mm) 6 = 7/8"(22.2mm) 2 3 Figure 3. Bun Thickness Adjustment Controls RECOMMENDED TEMPERATURES Recommended temperature setting for the platen heater is 600°F (315°C). Recommended temperature setting for the auxiliary heaters is 400°F (204°C). NOTE: The toaster is tested and shipped with the heaters set at the above recommended temperatures. 8 P/N 1010832 Rev. E 02/13 VERTICAL CONTACT TOASTER OPERATION (continued) TEMPERATURE CONTROL PANEL “Heat On” LED will blink on/off during warm-up and when either platen or auxiliary air heaters are calling for heat. To display the actual Platen temperature—providing it is over 440°F (227°C)—press the TEMP UP button. To display the actual Auxiliary Air Heater temperature— providing it is over 360°F (182°C)—press the TEMP DOWN button. SP - P 600 ˚F To switch the temperature display between Fahrenheit (°F) and Celsius (°C), press and hold the TEMP SCALE button for 5 seconds. TEMP UP TEMP DOWN ˚F ˚C TEMP SCALE TEMP UP TEMP DOWN ˚C TEMP SCALE PLATEN HEATER TEMPERATURE ADJUSTMENT 1. Turn the power on and wait for the Temperature Display to finish the power up sequence (Figure 4). POWER 2. Press and hold both TEMP UP and TEMP DOWN buttons for over 1 second until the display flashes the Platen setpoint temperature, then release. POWER 1. SP-P (Setpoint Platen) is displayed 2. Current Platen setpoint temperature setting is shown SP - A 400 3. Press the TEMP UP button to raise the setpoint temperature or press the TEMP DOWN button to lower the setpoint temperature. ˚F NOTE: The Maximum Platen setpoint temperature is 600°F (315°C). TEMP UP TEMP DOWN ˚F ˚C TEMP SCALE TEMP UP TEMP DOWN ˚C TEMP SCALE NOTE: If no change in temperature is made within 5 seconds, the display reverts back to the previous setpoint temperature. 4. Release the button when the desired setpoint temperature is displayed. POWER POWER AUXILIARY AIR HEATER TEMPERATURE ADJUSTMENT 3. SP-A (Setpoint Auxiliary) 4. Current Auxiliary Air setpoint is displayed temperature is shown 1. Turn the power on and wait for the Temperature Display to finish the power up sequence (Figure 4). USE LO 2. Press and hold both TEMP UP and TEMP SCALE buttons for over 1 second until the display flashes the setpoint temperature, then release. °F TEMP UP TEMP DOWN °C TEMP SCALE 3. Press the TEMP UP button to raise the setpoint temperature or press the TEMP DOWN button to lower the setpoint temperature. NOTE: The maximum Auxiliary Air Heater setpoint temperature is 400°F (204°C). POWER 4. Release the button when the desired setpoint temperature is displayed. 5. “LO” is displayed until platen temperature rises above 550°F (288°C) NOTE: If no change in temperature is made within 5 seconds, the display reverts back to the previous setpoint temperature. 6. “USE” is displayed when Platen setpoint temperature* is reached * Platen setpoint temperature must be between 460°F (238°C) and 600°F (315°). Figure 4. Temperature Power Up Sequence P/N 1010832 Rev. E 02/13 9 VERTICAL CONTACT TOASTER OPERATION (continued) Hi-Limit Reset Button A Hi-Limit Control turns off electrical power to the heater and control circuits if the unit overheats. To reset the control, allow 10-15 minutes for the unit to cool, then locate the Reset Button at the rear of the unit. Remove the black protective cap, press the Reset Button, and reinstall the protective cap (Figure 2). NOTE: If the Hi-Limit requires continuous resetting, contact your Authorized Service Agency. Fault Codes OLD STYLE CONTROL BOARD NEW STYLE CONTROL BOARD If the toaster control board resembles the OLD style shown here, refer to the Fault Message in Table 1. FAULT CODE ON DISPLAY FAULT CODE ON DISPLAY FAULT CODE DESCRIPTION “HI” Flashes on display The platen thermocouple is disconnected or open or the platen relay is shorted. Call for service. “HI” and “LO” flashes at cold start up The auxiliary thermocouple is disconnected or open. Call for service. “HI” and “USE” flashes after 30 minutes of preheat time The auxiliary thermocouple is disconnected or open or the auxiliary relay is shorted. Call for service. “CHEC” The electrical compartment ambient temperature is above 140° F (60° C). All heaters will shut off. Check for proper airflow. Call for service. “PO” The incoming voltage has dropped below 175 VAC. All heaters will shut off. Call for service. Table 1 If the toaster control board resembles the NEW style shown here, refer to the Fault Message in Table 2. POSSIBLE CAUSE(S) Err 1 Failed Control Board (Call for Service) Err 2 Failed Control Board (Call for Service) Err 3 The programming dip switches were not adjusted upon installation of the universal control board. The dip switches must be adjusted to match the toaster Mfg #. Refer to document P/N 1011052 for specific settings. Err 4 Platen Thermocouple is shorted to chassis ground (Call for Service) Err 5 Platen Thermocouple is Loose or Disconnected or Open (Call for Service) Err 6 Failed Control Board (Call for Service) Err 7 Failed Control Board (Call for Service) Err 8 Failed Control Board (Call for Service) Err 9 The programming dip switches were not adjusted upon installation of the universal control board. The dip switches must be adjusted to match the toaster Mfg #. Refer to document P/N 1011052 for specific settings. NOTE: If the dip switches were adjusted correctly, then the AC Isolator Board or its wiring is faulty. (Call for Service) Err 10 Failed Control Board (Call for Service) CHEC Ambient in electrical compartment has exceeded 140 F (60 C). Check for proper airflow. (Call for Service) Table 2 10 P/N 1010832 Rev. E 02/13 VERTICAL CONTACT TOASTER MAINTENANCE WARNING Turn the power off, unplug the power cord, and allow the unit to cool down for 30 minutes before performing any service or maintenance. 7. Open the front Conveyor Cover and firmly wipe the Belt Wrap from left to right and top to bottom with a clean towel dampened with Multipurpose Detergent Solution immediately followed by a second clean towel dampened with sanitizer. CAUTION To prevent damage to the unit, do NOT use abrasive cleaners on the release sheet or belt wrap. 8. Close the front Conveyor Cover, open the rear Conveyor Cover, and clean the Belt Wrap as described in Step 7. CAUTION Failure to use Release Sheets may result in damage to the unit and loss of warranty coverage. 9. Close the rear Conveyor Cover. Reinstall the Heat Shield, plug in the power cord, turn the unit on, count 15 seconds, then turn the unit off and unplug the unit. 10. Open the rear Conveyor Cover again and clean the newly exposed section of the Belt Wrap in the same manner as before. Close the Conveyor Cover. Daily NOTE: Pre-buttering/pre-oiling buns before feeding them into the toaster leads to butter/oil accumulation on the Release Sheet. This is normal, however excessive buildup can lead to buns sticking and burning. It is recommended that the Release Sheet be replaced or cleaned once for every 6 hours of operation. Dirty Release Sheets can be soaked in hot, soapy water for later cleaning. Continue to rotate Release Sheets, alternating between sides to maximize usage. 11. Open the front Conveyor Cover again and clean the newly exposed section of the Belt Wrap in the same manner as before. 12. Close the front Conveyor Cover and wipe down the outside of the toaster with a clean, damp, sanitized towel. 13. Install the Release Sheet by draping it over both sides of the Platen with the crease centered on the Platen. Tools Required: • Heat-Resistant Gloves • Clean Towels • Multipurpose Detergent Solution • Sanitizer Solution NOTE: To prolong the life of the Release Sheet, rotate it from the black side to the silver side on a daily or weekly basis. 14. Install the Bun Chute so the hooks are installed over the lower rear Support Rod. 1. Turn the power off, unplug the power cord, and clean the Release Sheet and Belt Wraps while they are warm. 15. Install the Heat Shield with the Release Sheet retainer clips securely over the Release Sheet and Platen. 2. Put on heat-resistant gloves and remove the Butter Wheel, Pan, and Heat Shield (Figure 1). 16. Reinstall the Butter Wheel and Pan, and plug in the unit. 3. Wash the Butter Wheel, Pan, and Heat Shield in a sink and wipe them with a damp sanitized towel and allow them to air dry. NOTE: Make sure the Heat Shield is activating the Conveyor Safety Interlock Switch. The conveyors will not rotate unless the Heat Shield is in place and the Conveyor Safety Interlock Switch is activated. 4. Remove the Release Sheet and place it on a clean, flat dry surface. 5. Wipe the silver side of the Release Sheet with a clean towel dampened with Multipurpose Detergent Solution immediately followed by a second clean towel dampened with sanitizer and allow it to air dry before continuing. NOTE: Check the Release Sheet to make sure it is not caught in the Conveyor. Additional Release Sheets can be purchased through your Authorized Service Agency under P/N 7000249 (3-Pack) or 7000250 (10-Pack). 6. Once the silver side is dry, repeat Step 5 on the black side of the Release Sheet. P/N 1010832 Rev. E 02/13 11 VERTICAL CONTACT TOASTER MAINTENANCE (continued) Replacing the Black and Silver Release Sheet (Every 4–6 Weeks) THICKNESS THICKNESS 6 3 2 1 4 5 6 NOTE: Depending on toaster usage and on how well it is cleaned daily, the black and silver Release Sheet should last between 30–45 days. Conveyor Belt Chains 5 4 1 1 = 1/2"(12.7mm) 2 = 5/8"(15.9mm) 3 = 11/16"(17.5mm) 4 = 3/4"(19.1mm) 5 = 13/16"(20.6mm) 6 = 7/8"(22.2mm) 2 3 Interlock Switch Conveyor Cover Assy. 1. Remove and discard the Release Sheet. Belt Wrap Pin 2. Lay a new Release Sheet on a clean, dry surface and fold it in half lengthwise and gently crease it at the fold using only your fingers (Figure 5). 3. Install the Release Sheet just as you would after Daily Cleaning. Figure 6. Removing Belt Wrap Upper Support Rod Fold over so ends meet. Belt Rotation Press Lightly with finger to form crease. Figure 5. Folding the Release Sheet Lower Support Rod Replacing the Belt Wraps (Every 3–6 Months) ION UT CA Belt Wrap Pin NOTE: Depending on toaster usage and how well they are cleaned daily, the Belt Wraps should last between 3–6 months. Additional Belt Wraps may be purchased from your Authorized Service Agency. Figure 7. Installing Belt Wrap 1. Turn the power off, unplug the power cord, and allow the unit to cool before proceeding. 2. Remove the Butter Wheel, Pan, and Heat Shield (Figure 1) and set the Bun Thickness Compression Knobs to 6 & 6. 3. Open both Conveyor Covers and pull the Belt Wrap Pin out of the zipper (Figure 6). INCORRECT CORRECT Figure 8. Aligning Belt Teeth 4. Remove and discard the old Belt Wrap(s). CAUTION Align the ends of the Belt Wrap properly (Figure 11) or the Belt Wrap may be damaged. 5. Clean both Conveyor Belt Chains just as you would clean the Belt Wraps during Daily Cleaning. 6. Install the new Belt Wraps around the Conveyor Belt Chains inside the rods with the zipper flap exposed and hanging down (Figures 7 & 8). CAUTION Position the Belt Wrap UNDER the upper and INCORRECT CORRECT lower support rods or damage to the unit may occur. 7. Close the Conveyor Cover(s), set the Bun Thickness Compression Knobs back to their normal settings and reinstall the Heat Shield, Butter Wheel, and Pan. 12 P/N 1010832 Rev. E 02/13 VERTICAL CONTACT TOASTER MAINTENANCE (continued) Checking the Conveyor Belt Chains (Every 3–6 Months) NOTE: The Bun Thickness Compression Knobs (Figure 3) must be set to “6 & 6” prior to measuring or removing or reinstalling the Conveyor Belt Chains. MEASURING CONVEYOR BELT CHAINS 1. Turn the unit off, unplug the power cord, and allow the unit to cool. 2. Remove the Bun Feeder, Butter Wheel, Pan, and Heat Shield (Figure 1) and set the Bun Thickness Compression Knobs to 6 & 6. 3. Open both Conveyor Covers and pull the Belt Wrap Pin out of the zipper (Figure 6). Figure 9. Measuring Conveyor Belt Chain 4. Remove the Belt Wrap. Rotation 5. Facing the toaster, locate the approximate centerpoint of the Conveyor Chain. Upper Support Rod 6. Pull the Conveyor Chain away from the edge of the toaster (Figure 9). Large Link P/N 0800121 7. Stand a U.S. Dime on end between the frame and the chain (Figure 9). Small Link P/N 0800204 8. If the gap is significantly wider than the coin, REMOVE links as described below. Figure 10. Removing Conveyor Belt Chain 9. Disconnect the Conveyor Belt Chain by squeezing any two links together and unhooking both ends one link (Figure 10). Needle-nose pliers may be used. REPLACING CONVEYOR BELT CHAINS 1. Turn the power off, unplug the power cord, and allow the unit to cool before proceeding. NOTE: There are two small 1/2” links on each side of the Conveyor Belt Chain. The rest are large 3/4” links. 2. Remove the Butter Wheel, Pan, and Heat Shield and set the Compression Control Knobs to 6 & 6. 3. Open both Conveyor Covers and pull the Belt Wrap Pin out of the zipper. 10. Remove one 1/2” link from the belt. 11. Reassemble the Conveyor Belt Chain onto the sprockets as described in Replacing Conveyor Belt Chains. 4. Remove and discard the old Belt Wrap(s). 5. Disconnect the Conveyor Belt Chain by squeezing any two links together and unhooking both ends of one link (Figure 10). 12. Measure the gap again to ensure it is not too tight. 6. Place the replacement Conveyor Belt Chain on the top sprockets with hook ends down. 13. Check the opposite side of the toaster using the same steps. NOTE: The ends of the hooks must point down (Figure 10). NOTE: If the Conveyor Belt Chain is too tight to be reassembled, remove an additional small 1/2” link and install a large 3/4” link in its place. This will shorten the Conveyor Belt Chain by 1/4” overall. 7. Wrap the Conveyor Belt Chain around the top and lower sprockets and connect by hooking both ends together. NOTE: Make sure the Conveyor Belt Chain is installed under the Upper Support Rod and over the Lower Support Rod. P/N 1010832 Rev. E 02/13 13 VERTICAL CONTACT TOASTER MAINTENANCE (continued) Checking the Roller Tensioners (every 3–6 months) MEASURING THE ROLLER TENSIONERS 1. Measure the Roller Tensioner on both inner Conveyor Covers (Figure 11) using a U.S Nickel. 2. The space between the inner Conveyor Cover and bottom of the Tensioner wheel should be 13/16” (2.1 cm) or the height of a U.S. Nickel. 3. Adjust or replace any damaged ones as recommended. Figure 11. Measuring Roller Tensioner REPLACING THE ROLLER TENSIONERS Acorn Nuts 1. Remove the acorn nuts and old Roller Tensioner Assembly (Figure 12). Weld Screws Tensioner Assy. 2. Replace Tensioner Assembly, and reassemble. 3. Make sure the spacers are placed inside the Tensioner arm. The spacers are smaller than the holes to allow the Tensioner to pivot freely. Spacers Tape Figure 12. Replacing the Roller Tensioner 14 P/N 1010832 Rev. E 02/13 VERTICAL CONTACT TOASTER TROUBLESHOOTING WARNING To avoid possible personal injury and/or damage to the unit, inspection, test and repair of electrical equipment should be performed by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. Use extreme care during electrical circuit tests. Live circuits will be exposed. Problem Possible Cause Corrective Action Control Display Flash- Platen temperature is below 440ºF es “LO” continuously (226ºC). Buns not toasting properly. Allow the unit to warm up for 30 minutes and then recheck. If the Control Display still reads “LO”, contact your maintenance person or Authorized Service Agency for service. Control display flashes “LO” continuously. Buns Burn. Failed Platen Thermocouple. Contact your maintenance person or Authorized Service Agency for service. Control Display flashes “PO” continuously. The power to the unit is below 190 volts. Failed Control Board Failed Control Board. Failed Transformer. Turn the power off and then back on. If the display still shows “PO”, check the power cord, plug, and outlet for damage. Reset the Circuit Breakers. Contact your maintenance person, Authorized Service Agency, or electrician for service. Control flashes “CHEC” continuously. Control Compartment temperature is Verify side vents on toaster are unblocked and not above 140ºF (60ºC). near other heating appliances. If problem still persists, contact your maintenance person or Authorized Failed Cooling Fan. Service Agency for service. Failed Control Board. Control Display flashes “HI” continuously. Buns burn. Failed Platen Solid State Relay. Control Display flashes “HI” continuously. Buns not toasting properly. Loose Platen Thermocouple connec- Re-secure the Platen Thermocouple connection to tion on Control Board or the Platen the Control Board. If the Control Display still reads Thermocouple is open. “HI,” check the Thermocouple for continuity. Contact your maintenance person or Authorized Service Failed Control Board. Agency for service. Contact your maintenance person or Authorized Service Agency for service. Failed Control Board. Failed Platen Thermocouple. Control Display Loose Auxiliary Thermocouple flashes “HI” & “LO” at connection on Control Board or cold start up, then “HI” Thermocouple is open. & “USE” after 20–30 minutes. Re-secure the Auxiliary Thermocouple connection to the Control Board. If the Control Display still reads “HI” & “LO” or “HI” & “USE,” check Thermocouple for continuity. Contact your maintenance person or Authorized Service Agency for service. No Control Display. Unit not plugged in. Plug unit into the proper electrical outlet. Hi-Limit control has tripped. Allow unit to cool and reset the Hi-Limit control. If it trips again, contact your maintenance person or Authorized Service Agency. Circuit Breakers turned off or tripped. Reset Circuit Breakers. If they trip again, check the Damaged electrical outlet, plug, or cord, plug, and outlet for damage. cord. Power Switch damaged. Contact your maintenance person, Authorized Service Agency, or electrician. P/N 1010832 Rev. E 02/13 15 VERTICAL CONTACT TOASTER TROUBLESHOOTING (continued) Problem Conveyor does not turn. Buns not toasting adequately Possible Cause Corrective Action Safety Interlock Switch is not activated. Reposition the Heat Shield properly. Heat Shield is bent or damaged. Replace Heat Shield. Damaged or Missing Roller Tensioner(s). Adjust or replace Roller Tensioner(s). Conveyor Belt/Chain has stretched. Chain skipping on sprockets. Measure and adjust the Conveyor Belt Chains as described in the Maintenance section of this manual. Motor Drive Chain came off Sprocket(s). Reinstall Drive Chain. Drive Chain needs lubrication. Lubricate chain. Drive Motor has overheated. Allow unit to cool and check Conveyor(s) for obstructions or binding at sprockets. Measure and adjust Conveyor Belt(s) as described in the Maintenance section of this manual. Drive Motor has failed. Contact your maintenance person or Authorized Service Agency for service. Compression Settings are incorrect. Use the recommended settings. Set Heel to 2 and Crown to 6. Temperature Setting is incorrect. Verify that the Platen (SP-P) is set to 600°F (320°C) and the Auxiliary (SP-A) is set to 400°F (204°C). For making changes in the setpoint temperature, see the Installation section of this manual. Release Sheet is worn or needs cleaning (replace every 4–6 weeks.) Inspect Release Sheet for cleanliness, worn sports, tears, or wrinkles. Clean or replace Release Sheet as described in the Maintenance section of this manual. Belt Wraps are worn or need cleaning (replace every 3–6 months). Replace or clean Belt Wraps as described in the Maintenance section of this manual. Belt Wraps are not tacky/sticky. Clean or replace Belt Wraps as described in the Maintenance section of this manual. Buns do not meet specifications. Contact your bun supplier. 16 P/N 1010832 Rev. E 02/13 VERTICAL CONTACT TOASTER TROUBLESHOOTING (continued) Problem Crowns and/or Heels must be forced into the toaster. Buns sticking and burning. New Conveyor Belt Wraps do not fit. Possible Cause Corrective Action Belt Wraps not being cleaned properly. Clean Belt Wraps as described in the Maintenance section of this manual. Conveyor Belt Wraps are not tacky/ sticky (replace every 3–6 months). Clean Belt Wraps. If the Belt Wraps are too worn, replace them as described in the Maintenance section of this manual. Belt Wraps are dirty, worn, or damaged (replace every 3–6 months). Clean or replace Belt Wraps as described in the Maintenance section of this manual. Release Sheet is not being cleaned properly. Clean both sides of the black and silver Release Sheet as described in the Maintenance section of this manual. Release Sheet is not being reversed as required. Reverse the Release Sheet or replace Release sheet as described in the Maintenance section of this manual. Release Sheet is dirty, worn, or damaged (replace every 4–6 weeks). Clean or replace Release Sheet as described in the Maintenance section of this manual. Conveyor Belt Chains are skipping on Sprockets. Measure and adjust the Conveyor Belt Chains as described in the Maintenance section of this manual. Safety Interlock Switch is not being activated by the Heat Shield. Heat Shield is ajar. Reposition Heat Shield. Belt Wraps slipping over Conveyor Belt Chains. Remove Belt Wraps and clean the Conveyor Belt Chain links and Belt Wraps as described in the Maintenance section of this manual. Roller Tensioner(s) damaged or missing. Reinstall or replace Roller Tensioner(s) as described in the Maintenance section of this manual. Drive Motor stalls intermittently. Contact your maintenance person or an Authorized Service Agency for service. Compression Settings are incorrect. Use the recommended settings. Set Heel to 2 and Crown to 6. Buns are not inserted into the toaster properly. Buns must be inserted with the cut sides facing each other on the correct Heel or Crown side. Compression Settings are incorrect. Set Compression Knobs to 6 and 6 when replacing Belt Wraps or when adjusting Conveyor Belt Chains. Belt Wraps not installed correctly. Install Belt Wraps inside the Conveyor Support Rods with the zipper flap exposed and hanging down. Using incorrect or damaged Belt Wraps. Replace with OEM P/N 7000192 only. P/N 1010832 Rev. E 02/13 17 Heat Shield is damaged. Replace if necessary. If the Safety Interlock Switch is damaged, contact your maintenance person or Authorized Service Agency for service. VERTICAL CONTACT TOASTER TROUBLESHOOTING (continued) Problem Toaster makes unusual sounds. Possible Cause Corrective Action Compression Settings are too tight. Set Compression Settings to the correct (or larger) setting. Conveyor Belt Wrap is installed incorrectly. Belt Wraps must be installed as described in the Maintenance section of this manual. Belt Wrap Pin rubbing on housing. Center the Pin in the Belt Wrap zipper. Roller Tensioner(s) bent or missing. Measure, adjust, or replace the Roller Tensioner(s) as described in the Maintenance section of this manual. Conveyor Belt Chains have stretched. Measure and adjust the conveyor Belt Chains as described in the Maintenance section of this manual. Conveyor Belt Chains adjusted incorrectly. Sugar and/or Carbon has accumulated inside the Conveyor Belt Wrap and between the Conveyor Belt chain and Tensioner Slide Rails. Remove Belt Wraps and clean Conveyor Belt Chain links just as you clean the Belt Wraps daily, and then clean the Slide Rails on the Tensioners. Then clean the Belt Wrap on both sides before reinstalling it. Motor Drive Chain needs lubrication. Lubricate the Drive Chain carefully at least once a year. A Conveyor Shaft bearing is binding. Contact your maintenance person or Authorized Service Agency for service. 18 P/N 1010832 Rev. E 02/13 VERTICAL CONTACT TOASTER WIRING DIAGRAM Pictorial Wiring Diagram P/N 1010832 Rev. E 02/13 19 VERTICAL CONTACT TOASTER WIRING DIAGRAM (continued) 20 P/N 1010832 Rev. E 02/13 VERTICAL CONTACT TOASTER REPLACEMENT PARTS Parts Identification Platen Safety Interlock Switch Front Auxiliary Air Heater Rear Auxiliary Air Heater Auxiliary Air Thermocouple Drive Chain Idler Sprocket Transformer Drive Sprocket Drive Sprocket Auxiliary Relay Platen Thermocouple Platen Relay Temperature Control Hi-Limit Capillary Probe Drive Motor Assembly Fan Blade Auxiliary Air Thermocouple Hi-Limit Control Rocker Switch P/N 1010832 Rev. E 02/13 21 VERTICAL CONTACT TOASTER REPLACEMENT PARTS (continued) 107 106 105 64 3 117 112 111 115 116 122 38 118 120 29 114 119 116 52 35 76 66 34 83 98 61 ON UTI CA 101 3 33 81 PLATEN P L A T E N A U X I L I A R Y AUXILIARY 60 28 55 TE M UP P PO TE DO MP WN °F °C TE SC MP ALE 83 WE R 63 48 82 8 93 86 10 22 P/N 1010832 Rev. E 02/13 VERTICAL CONTACT TOASTER REPLACEMENT PARTS (continued) 100 36 67 16 71 42 72 70 97 70 54 70 67 12 92 83 62 53 27 26 65 17 18 67 19 56 TE M UP P 32 PO TE DO MP WN 70 75 67 80 91 20 89 90 42 70 °F °C T SCEMP ALE 74 67 104 WE R 17 17 19 72 21 12 39 84 83 43 11 23 68 71 P/N 1010832 Rev. E 02/13 23 46 87 17 70 24 23 22 58 VERTICAL CONTACT TOASTER REPLACEMENT PARTS (continued) 2 65 49 16 1 30, 94 37 70 5 4 67 34 31, 95 50 9 41 79 78 65 7 6 7 88 51 57 4 40 31 1 62 95 85 76 40 44 67 6 49 30 65 9 41 94 67 89 76 96 45 65 6 7 85 24 83 P/N 1010832 Rev. E 02/13 VERTICAL CONTACT TOASTER REPLACEMENT PARTS (continued) Item 1 Part No. 2 3 0011266 0800204 0800121 2150117 0011491 4 5 6 7 8 9 10 11 12 16 16A 0010475 0800332 7000207 7000199 0011444 2150118 2100212 7000739 7000296 7000167 7000224 17 18 19 20 2150181 2150187 0011299 0011300 21 22 0503589 7000240 7000271 23 2150173 2150112 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 7000882 2150109 405K125 4010187 7000192 7000186 0503496 0503497 1001006 1001047 2100253 0011552 4050214 0021170 7000249 7000250 0021169 7000121 41 42 43 44 45 46 0021207 7000176 4030332 0011573 0503455 0503590 Description Conveyor Belt (Incl. Items below) 1/2” Pitch Link, Small 3/4” Pitch Link, Large Idler Shaft Conveyor Cover Assy. (Incl. #29, 52, 61, & 76) Tensioner Assy. (Incl. #40, 76, & 85) Rod, Conveyor Cover Sprocket w/ Setscrew Spacer Kit (Pack of 2) Control Housing Cover Assy. Drive Shaft Handle Control Board Kit Ball Bearing (Pack of 2) Bearing & Retainer Kit Bearing & Retainer Kit (Incl. 6 of #16) Drive Sprocket Drive Chain Idler Sprocket & Bearing Bracket, Idler Sprocket Assy. (Incl. #19, 87, 89, 90, & 91) Bracket, Motor Mounting Drive Motor Kit, 9 RPM 50/60 Hz (Incl. #58) (Mfg. No. 9210114 only) Drive Motor Kit, 3 RPM (Incl. #58) (Mfg. No. 9210118 only) Sprocket w/Setscrew, Motor (Mfg. No. 9210114 only) Sprocket w/Setscrew, Motor (Mfg. No. 9210118 only) Rocker Switch Kit Drive Sprocket, Rear Relay, Solid State Transformer Conveyor Belt Wrap (Pack of 2) Roller Tensioner Assy. (Pack of 2) Tensioner Bracket, Right Tensioner Bracket, Left Label, Control Label, Dial Compression Knob, Control End Housing Cover Assy. Thermocouple Assy. Weldment, End Housing Release Sheet (Pack of 3) Release Sheet (Pack of 10) Control Housing Slide Rail Kit (Includes 2 Slide Rails for tensioners) Conveyor Cam Thermocouple Retainer Kit High Limit Control Idler Shaft Assy. (Top, Front) Tension Spring, Inner Bracket, Motor P/N 1010832 Rev. E 02/13 Qty. Item 2 2 38 1 2 47 48 49 50 51 52 53 54 55 56 57 58 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 4 4 8 2 1 3 2 1 1 6 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 2 1 1 2 1 1 1 1 2 2 2 1 1 4 1 25 Part No. 0700580 0503677 0503624 4030349 7000165 7000288 2100252 0503359 0503150 303P127* 4060355 0503533 4000170 040K251 05P2199* 0500464 040P138* 0011528 325P163* 100P864* 308P183* 304P105* 406P107* 308P143* 310P103* 310P157* 308P101* 306P101* 306P123* 308P145* 100P900* 325P104* 325P109* 308P124* 10P1022* 310P136* 308P133* 308P157* 308P181* 218P145* 331P103* 306P105* 331P106* 212P118* 331P101* 300P102* 210K230 0503495 0503507 2100259 4010107 0700452 306P104* 4000202 0503115 1001056 2120147 Description Wire Set (not shown) Bun Chute Bun Chute (Mfg. No. 9210114 only) Auxiliary Heater, 675W/208V Auxiliary Thermocouple Kit Platen (208V) Tape Bracket, Relay Heater Clip Hinge Pin, Belt Wrap Terminal Block Bracket, Auxiliary Thermocouple Fan Blade, Motor Strain Relief, Domestic (Incl. #63) Spacer Retainer, Bearing Locknut, 1/2” Heat Shield Assy. Setscrew, 1/4-28 x 5/16” Label, Caution Hot Screw, Hex, #8-32 x 3/8” Nut, #4-40, “KEPS” Cable Tie Nut, #8-32, “KEPS” Screw, Hex, #10-32 x 1/4” Washer, #10 Nut, #8-32 Nut, Hex, #6-32 Screw, #6-32 x 7/8” Nut, Hex Acorn, #8-32 Label, Service Washer, 1/4” Screw, 1/4-20 x 1/2” Screw, 1-Way, #8-32 x 1/2” Label, Heaters Screw, #10-32 x 1-1/4” Screw, #8-32 x 1/4” Screw, Tap, #8-32 x 3/8” Screw, Flat Hd., #8-32 x 3/8” Cover, Leg, Bumper Shoulder Bolt, 5/16-18 x l” Screw, #6-32 x 1/2” Lockwasher, 5/16” Flat Washer, 5/16” Nut, Hex, 5/16-18 Nut, Tinnerman Bumper, Recess Leg, 1” (Qty. of 4) Retainer, Tensioner Bracket, RH Retainer, Tensioner Bracket, LH Slide Bar Interlock Switch Power Cord NEMA 6-20P Screw, #6-32 x 1/4” Fan Duct, Fan Label, Crown & Heel Leg Spacers Qty. 1 1 1 2 1 1 4 1 2 2 1 1 1 1 4 2 1 1 8 1 2 4 1 6 4 6 3 2 2 14 1 4 4 1 1 4 1 20 4 4 1 8 1 1 1 2 1 1 1 4 1 1 6 1 1 1 4 VERTICAL CONTACT TOASTER replacement parts (continued) REPLACEMENT PARTS (continued) Item 104 105 106 107 111 112 114 115 116 117 118 119 120 122 Part No. Description Qty. 4060374 Ground Lug 1 0021320 Butter Wheel Roller 1 0503987 Butter Pan 1 0021507 Bun Feeder 1 308P157 Screw, #8-32 x 3/8” 7 2150204 Bearing, Shaft, 1/2” 4 2150212 Sprocket, 12 Tooth 1 2150207 Sprocket, 28 Tooth 1 2120149 Spacer, Nylon 2 0503891 Housing 1 0400295 Plug, Pry Out 1 0011553 Shaft Assembly 1 2150205 Chain Drive 1 7000692 Shaft Coupling Kit (Incl. Items Below) 1 2150201 Shaft, Drive 1 2150202 Coupler 1 123 2140152 Lubricant (not shown) 1 * Sold only as packages of 10. 26 P/N 1010832 Rev. E 02/13 VERTICAL CONTACT TOASTER NOTES P/N 1010832 Rev. E 02/13 27 LIMITED WARRANTY Equipment manufactured by Roundup Food Equipment Division of A.J. Antunes & Co. has been constructed of the finest materials available and manufactured to high quality standards. These units are warranted to be free from electrical and mechanical defects for a period of one (1) year from date of purchase under normal use and service, and when installed in accordance with manufacturer’s recommendations. To insure continued operation of the units, follow the maintenance procedures outlined in the Owner’s Manual. During the first 12 months, electro-mechanical parts, non-overtime labor, and travel expenses up to 2 hours (100 miles/160 km), round trip from the nearest Authorized Service Center are covered. 1.This warranty does not cover cost of installation, defects caused by improper storage or handling prior to placing of the Equipment. This warranty does not cover overtime charges or work done by unauthorized service agencies or personnel. This warranty does not cover normal maintenance, calibration, or regular adjustments as specified in operating and maintenance instructions of this manual, and/or labor involved in moving adjacent objects to gain access to the equipment. This warranty does not cover consumable/wear items. This warranty does not cover damage to the Load Cell or Load Cell Assembly due to abuse, misuse, dropping of unit/shock loads or exceeding maximum weight capacity (4 lbs). This warranty does not cover water contamination problems such as foreign material in water lines or inside solenoid valves. It does not cover water pressure problems or failures resulting from improper/incorrect voltage supply. This warranty does not cover Travel Time & Mileage in excess of 2 hours (100 miles/160 km) round trip from the nearest authorized service agency. 2.Roundup reserves the right to make changes in design or add any improvements on any product. The right is always reserved to modify equipment because of factors beyond our control and government regulations. Changes to update equipment do not constitute a warranty charge. 3.If shipment is damaged in transit, the purchaser should make a claim directly upon the carrier. Careful inspection should be made of the shipment as soon as it arrives and visible damage should be noted upon the carrier’s receipt. Damage should be reported to the carrier. This damage is not covered under this warranty. 4.Warranty charges do not include freight or foreign, excise, municipal or other sales or use taxes. All such freight and taxes are the responsibility of the purchaser. 5.THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, EACH OF WHICH IS HEREBY EXPRESSLY DISCLAIMED. THE REMEDIES DESCRIBED ABOVE ARE EXCLUSIVE AND IN NO EVENT SHALL ROUNDUP BE LIABLE FOR SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGES FOR THE BREACH OR DELAY IN PERFORMANCE OF THIS WARRANTY.