Prince Castle 197-BK Series User manual

INSTRUCTIONS
Vertical Contact Toaster
197-BK, 296 & 297
Series
TABLE OF CONTENTS PAGE
Installation.................................................................... 2
Operation ...................................................................... 2
Adjustments................................................................. 3
Cleaning ....................................................................... 4
Parts List................................................................... 5-8
Troubleshooting ........................................................... 9
Wiring Diagram ............................................................ 9
ELECTRICAL SPECIFICATIONS
Volts Hz Watts Amps
110/120 60 1700 15.5
220 50/60 1700 7.39
OPERATING
INSTRUCTIONS
355 East Kehoe Blvd. zCarol Stream, IL 60188
Tel: [phone] zFax: [phone]
Toll Free: 1-800-PCASTLE
Printed in 2001
Prince Castle Inc. (REV. A) 297-501
LIMITED WARRANTY
This product is warranted to be free from defects in
material and/or workmanship for a period of two (2) years
from date of original installation, not to exceed 30 months
from date of shipment from our factory. Any part or
component which proves to be faulty in material and/or
workmanship within the warranty period will be replaced
or repaired (at the option of Prince Castle, Inc.) without
cost to the customer for parts or labor
This warranty is subject to the following exceptions/
conditions:
zService must be performed by an authorized Prince
Castle Service Center.
zAny use of non-genuine Prince Castle spare parts
voids this warranty.
zThis equipment is portable; charges for on location
service (e. g., trip charges, mileage) are only
included in the provisions of this warranty for
a failure which occurs within 30 days of
installation.
zAll labor shall be performed during regular working
hours. Overtime premium will not be covered.
zDamage caused by carelessness, neglect, and/or
abuse (e.g., using wrong current, dropping, tamper-
ing with or altering electrical components, or improp-
er cleaning) is not covered by the terms of this
warranty. Equipment damaged in shipment, by fire,
flood or an act of God is not covered.
zNormal adjustments as outlined in this manual are
not covered under warranty.
zMotors that fail due to the lack of monthly
lubrication may not be covered under warranty.

INSTALLATION
1. After you have removed the toaster from the carton,
inspect the unit for signs of damage. If there is
damage to the unit:
zNotify carrier within 24 hours after delivery.
zSave carton and packing material for inspection
purposes.
zContact your Prince Castle dealer or the Prince
Castle Customer Sales Department at 1-630-462-
8800 if purchased directly.
2. Verify that all parts have been received.
zSlim-Line Bun Toaster and conveyor assembly.
zRelease Sheet Kit–located in a 14” box.
zCrumb Tray–taped to the front of the conveyor.
3. Place toaster on flat surface. Remove protective
covering.
4. Lift conveyor off conveyor guide rails and set aside.
Remove all packing materials (nylon tape, foam block,
plastic coating on sheet metal, and black rubber
packaging spacers) from conveyor and conveyor
guides.
5. Place the teflon sheet over the top of the platen
housing, making sure to have three inches of over-
hang.
6. Slide the release sheet holding bracket onto the top of
the platen housing.
7. Attach conveyor to the toaster by sliding the four pins
(conveyor slides) on the conveyor housing into the
four conveyor guides. Lower the conveyor housing
until it is securely in place.
8. Hook the back end of the crumb tray onto the bar
located below the conveyor assembly.
9. Plug unit into a properly grounded receptacle.
OPERATION
1. Turn the Power switch to the “On” position. The
orange indicator light will illuminate. Allow 30 minutes
for platen to reach operating temperature.
2. Place a sample run of the product being toasted into
the top of the conveyor housing. The side to be
toasted should face the platen.
3. The toasted product will be dispensed automatically
from the bottom of the conveyor assembly
.
4. Verify that product meets acceptable standards. If not,
see adjustment section.
2
Holding
Bracket
Conveyor
Guides
Release
Sheet
3-inch
Overhang
Power
Switch

Bun Compression:
The toaster platen can be adjusted to provide the neces-
sary compression needed on various products.
zTurn the two platen adjustment knobs clockwise to
compensate for use on thicker bread products. Turn
the two platen adjustment knobs counter clockwise
for thinner products. The numbers on the front of the
end and moter housing will indicate the settings, 1 for
thinnest product, 5 for thickest.
Platen Temperature:
The temperature of the platen can be adjusted to compen-
sate for darker or lighter toasting requirements.
zTurn the thermostat adjustment knob clockwise for
darker toasting. Turn the thermostat adjustment knob
counter clockwise for lighter toasting.
IMPORTANT: Allow 15 minutes for toaster to stabilize
after adjusting the thermostat.
3
ADJUSTMENTS
Conveyor and Motor Gears:
There will be a small clearance between the conveyor gear
and motor gear when properly aligned. Improper alignment
will cause the conveyor to periodically bind.
Tools Needed: 3/32” Allen wrench
Wicking grade thread locking fluid
1. Working from the “back side” of the toaster, loosing
the 2 setscrews at the bottom of the conveyor guide
until they are even with the conveyor stop. Note: the
conveyor assembly may need to be removed for
easier access.
2. Use the Allen Wrench to tighten the left setscrew (end
housing side) until the setscrew just touches the
conveyor slide.
3. Tighten the right set screw (motor housing side) until
the bottom of the conveyor housing is parallel to the
top of the base.
4. Carefully tighten each setscrew another 1/2 turn.
5. Remove the conveyor assembly.
6. Apply a drop of wicking grade thread locking fluid to
each setscrew.
7. Replace conveyor assembly
Gears
Properly
Mesh
Platen
Adjustment
Knobs
Thermostat
Knob
Top of the
#10-32 Set Screw
Both Sides
3/32 Hex
Head Key

CLEANING
CAUTION: This is not jet-water approved, and
should not be cleaned with a water hose or
jet spray.
CAUTION: Do not immerse in water.
1. Turn off both the heater and motor switches and
unplug the toaster.
2. Allow platen to cool for 60 minutes before cleaning.
3. Remove the conveyor assembly.
4. Wipe the conveyor with a damp cloth. For the chain
use a soft bristle brush.
5. Remove the release sheet and lay it on a flat surface.
Thoroughly clean both sides with a damp cloth
making sure all carbon build up is removed. Allow to
air dry.
IMPORTANT: Rotate two sheets daily for longer life.
Sheets last 4-6 months based on care and volume of
product toasted.
6. Use a damp cloth to remove any carbon build up on
the platen surface.
IMPORTANT: Do not use sharp objects, scotch brite
pads, scouring pads, or abrasive cleaners on the platen,
or teflon release sheets as it will cause irreparable
damage.
4
PREVENTIVE MAINTENANCE
(MOTOR)
Note: See the drawing for oil port hole location.
Oil
Port
To extend the life of your motor,have a factory
authorized service technician add 2-3 drops high
temperature motor oil on a monthly basis.

5
FRONT VIEW PARTS LIST
ITEM PART NUMBER DESCRIPTION
1 78-184S Power Lighted
Rocker Switch
2 197-185S Platen Adjustment Knob
(Pkg of 2)
3 70-012 Thermostat Knob
4 197-232 Foot
5 197-124 Conveyor Guide
6 197-472 Motor Housing
* 197-475 Overlay Motor Housing
197-491 Overlay Motor Housing
(197-BK)
* 197-484 Overlay End Housing
* 197-259 Release Sheet
Conversion Kit, 197/297
* 197-402 Release Sheet
Conversion Kit, 296
* 197-260 Release Sheets
(Pkg of 2), 197/297
* Not Shown
TROUBLE SHOOTING
PROBLEM CAUSE SOLUTION
Unit will not heat up. No power to unit. Ensure power cord is connected to
Power rocker switch proper Receptacle and the power inlet.
light off. Inoperable power cord. Replace power cord.
Loose connection on power switch. Tighten power switch connections.
Inoperable power switch. Replace power switch.
Unit will not heat up. Inoperable thermostat. Replace thermostat.
Power rocker switch light on. Inoperable platen. Replace platen.
Unit heats up, but the Loose motor switch connection. Tighten motor switch connection.
conveyor does not run. Inoperable motor. Replace motor.
Stripped drive gear. Replace drive gear.
Loose chain sprockets Adjust and tighten sprockets.
Gears not meshing. Adjust conveyor set screws (See
Conveyor Adjustments on page 3).
Inoperable motor switch. Replace switch.
Unit under and over Inoperable thermostat. Replace thermostat.
heats (does not respond to
thermostat adjustments).
Buns under or over done. Check platen adjustment. Adjust platen for proper compression
(See Platen Adjustments on page 3).
Check platen temperature. Adjust thermostat for proper temperature.
(See Thermostat Adjustment on page 3).
1
2
3
4
5
6

6
PARTS LIST
ITEM PART NUMBER DESCRIPTION
1 197-461 Right Side Shaft Carrier Assy.
2 197-463 Left Side Shaft Carrier Assy.
3 197-459 Right Side Shaft
Carrier Adjustment Assy.
4 197-457 Left Side Shaft
Carrier Adjustment Assy.
5 81-015 Compression Spring
6 197-467 Conveyor Slide
7 197-280 Shaft Assy.
8 197-465 Driven Shaft
9 197-302 Sprocket Kit (Pkg of 2)
10 89-684 Complete Chain Assy.
11 89-590 Single Conveyor Chain Link
12 197-7S Black Handle With Screw
13 197-455S Complete Conveyor Assy.
* 297-089 Reflector (Not Shown)
CONVEYOR ASSEMBLY
1
2
3
4
5
5
6
6
6
7
89
9
10
11
12
13
6

7
PARTS LIST
ITEM PART NUMBER DESCRIPTION
1 197-436S Gear Kit (20/40Second)
197-476S Gear Kit (12 Second)
197-477S Gear Kit (14 Second)
197-437S Gear Kit (30 Second)
196-026S Gear Kit (55 Second)
2 197-114 Motor Cover
3 197-473 End Housing
4 76-225 Slotted Pan Head Screw
5 197-131 Guard
6 197-33 Crumb Tray
8 73-007 Hex Nut
197-16 Conveyor Stop
76-165 Set Screw
9 76-640 Screw
10 197-96 Left Side Bun Fence
11 73-008 Self Locking Hex Nut
73-030 Hex Nut
79-016 Flat Washer
76-033 Slotted Flat Head Screw
12 76-640 Screw
13 197-13 Lead Pan Weldement
14 197-97 Right Bun Fence
15 197-430S Platen (120 Volt) (297)
197-431S Platen (220-230 Volt (297)
196-023S Platen (120 Volt) (296)
297-032S Platen (200 Volt) (297)
16 197-95 Tray Support
17 72-280S Line Cord
72-332S Line Cord (Canada)
REAR VIEW
4
1
56
8
9
10
15
12
13
14 11
16
17
2
3

8
INTERNAL COMPONENTS
PARTS LIST
ITEM PART NUMBER DESCRIPTION
1 76-300 Slotted Pan Head Screw
2 87-029S Motor (120 Volt)
87-028S Motor (200-240 Volt)
3 73-031 Hex Nut
4 79-033 Washer
5 76-051 Slotted Binder Head Screw
6 79-055 Flat Washer
7 76-040 Slotted Binder Head Screw
79-017 Split Lock Washer
73-030 Hex Nut
8 76-150 Slotted Pan Head Screw
79-094 Flat Washer
9 79-016 Flat Washer
76-095 Slotted Binder Head Screw
10 197-90 L. H. Side Plate Weldement
w/ Adjustment Screw
197-89 R.H. Slide Plate Bracket
w/Adjustment Screw
11 197-428 Baffle (Motor Housing)
197-429 Baffle (End Housing)
12 196-19 Housing
13 197-140 Thermostat With Knob
1
2
3
4
5
6
7
8
9
10
11
12
13

WIRING DIAGRAM
TROUBLE SHOOTING
PROBLEM CAUSE SOLUTION
Unit will not heat up. No power to unit. Ensure power cord is connected to
Power rocker switch proper Receptacle and the power inlet.
light off. Inoperable power cord. Replace power cord.
Loose connection on power switch. Tighten power switch connections.
Inoperable power switch. Replace power switch.
Unit will not heat up. Inoperable thermostat. Replace thermostat.
Power rocker switch light on. Inoperable platen. Replace platen.
Unit heats up, but the Loose motor switch connection. Tighten motor switch connection.
conveyor does not run. Inoperable motor. Replace motor.
Stripped drive gear. Replace drive gear.
Loose chain sprockets Adjust and tighten sprockets.
Gears not meshing. Adjust conveyor set screws (See
Conveyor Adjustments on page 3).
Inoperable motor switch. Replace switch.
Unit under and over Inoperable thermostat. Replace thermostat.
heats (does not respond to
thermostat adjustments).
Buns under or over done. Check platen adjustment. Adjust platen for proper compression
(See Platen Adjustments on page 3).
Check platen temperature. Adjust thermostat for proper temperature.
(See Thermostat Adjustment on page 3).
9