Avtec Tray-Trac, TTB2 Installation Manual
INSTALLATION INSTRUCTIONS/
OPERATORS MANUAL
This manual provides
Installation & Operating instructions for
TRAY-TRAC
SYSTEM
NOTIFY CARRIER OF DAMAGE AT ONCE.
It is the responsibility of the consignee to inspect the
container upon receipt of same and to determine
the possibility of any damage, including concealed
damage. Avtec suggests that if you are suspicious of
damage to make a notation on the delivery receipt. It will be the responsibility of the consignee to
le a claim with the carrier. We recommend that you
do so at once.
Manufacture Service/Questions 888-994-7636.
Information contained in this document is known to be
and accurate at the time of printing/creation. Unified Brands
recommends referencing our product line websites,
unifiedbrands.net, for the most updated product information and
specifications.
PP MNL0803
current
1055 Mendell Davis Drive
Jackson, MS 39272
888-994-7636, fax 888-864-7636
unifiedbrands.net
TABLE OF CONTENTS
INSTALLATION INSTRUCTIONS
I. SERVICE CONNECTIONS . . 1
A. Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Mobile Tray-Trac [Casters] 1
2. Stationary Tray-Trac [Legs] 1
B. Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Mobile Tray-Trac [Casters] 1
2. Stationary Tray-Trac [Legs] 1
C. Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Hot Food Well Drain . . 1
2. Refrigeration Drain . . 1
OPERATING INSTRUCTIONS
I. STANDARD CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. Modular Distribution Systems .......................................................................................
B. Start/Stop Stat ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
III. ACCESSORIES AND CONTROLS 2
A. Momentary Foot Stop Switch 2
B. Fluorescent Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Hot Food Wells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Cold Tops and Cold Pans
E. Checker Audio Call System 3
F. Timer Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
..
2
3
USER-MAINTENANCE INSTRUCTIONS
IV. PERIODIC CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
A. All Work Surfaces 4
B. Tray Carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C. Hot Food We ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
D. Cold Tops and Cold Pans
V. PERIODIC MAINTENANCE 4
A. Gear Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C. Tray Carrier Drive Chain
D. Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E. Torque Limiter Sprocket 4
F. Refrigeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Grounding Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Grounding Instructions for Permanently Connected Appliances . . . . . . . . . . . . . . . . . . . . . 6
VI. EMERGENCY PARTS LIST . . 7
Randell Manufactured Drop in Units Parts List ............................................................................... . 7
Mechanical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hot Food Drop Ins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HOT Food Well Pa
Fluorescent Light Fixture Parts . 9
Electrical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Component Identification Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
rts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . 4
4
VII. SPECIFIC TECHNICAL DATA AND DIAGRAMS
A. Electrical Schematics
1. Carousel Motor Controls . . 12
VIII. ADDITIONAL INFORMATION
A. Warranty
13
INSTALLATION INSTRUCTIONS
I. SERVICE CONNECTIONS
A. Electrical
1.Mobile Tray-Trac [Casters]
a.Power from above
A male connection is provided at the top of
the service pylon. This is the power inlet to
the Tray-Trac System. A drop cord with
matching connector body is supplied for
connecting to the ceiling. To complete the
connection, turn main breakers in each
electrical distribution system OFF, insert
connector body into male receptacle fully
and lock into position with locking collar.
Turn breakers ON to energize Tray-Trac.
b.Power from below
A power supply cord is provided from the
back of the Service Terminal Box to a
matching receptacle in the floor box. To
complete the connection, turn main
breakers in each electrical distribution
system OFF, insert plug fully into receptacle
and lock into position with locking collar.
Turn breakers ON to energize Tray-Trac.
2. Stationionary Tray-Trac [Legs]
a.Power from above
Turn main service breakers in power
supply panel box to OFF while making
connection. The electrical contractor is
to bring rigid or flexible conduit down
from the ceiling into the top of the
service enclosure.
provided within the service enclosure to
which the
connects.
b.Power from below
Turn main service breakers in power
supply panel box to OFF while making
connection. Electrical contractor is to
bring rigid or flexible conduit into back or
bottom of Service Terminal Box. A
terminal is provided within the Service
Terminal Box to which the electrical
contractor connects.
B. Water
1.Mobile Tray-Trac [Casters]
The plumbing connection[s] is usually made
with a flexible hose and quick-disconnect
assembly. To connect quick-disconnect,
slide locking collar on female connector
back and insert male connector. The
A terminal is
electrical contractor
locking collar will snap forward when male
connector is fully inserted. Both halves of
the quick-disconnect are equipped with
self-contained shut-off valves stop the flow
of water as soon as it is uncoupled.
However, we recommend installing a
manual shut-off valve immediately before
the quick-disconnect/hose assembly.
a.Service from above
Install the union end of the water
connector [hose] assembly to the supply
piping in the ceiling.
disconnect male coupling into female on
Tray-Trac unit as described previously.
b.Service from below
A water connector
supplied on the Tray-Trac. If an AVTEC
floor box is supplied, connect the supply
piping to
mounted in AVTEC floor box, then insert
male quick-disconnect as described
above. If an AVTEC floor box is not
supplied, connect female quick-disconnect
to supply piping shut-off valve.
2.Stationary Tray-Trac [Legs]
The plumbing connection[s] is usually
terminated with a 1/4 turn shut-off valve,
which may be located in the base of the unit
[connection from below] or in the service
pylon
plumbing contractor then connects directly
to this valve with rigid pipe.
C. Drains
1.Hot Food Well Drain
a.Direct service connection
Drain normally connected with hard piping
to open floor drain or other waste line.
b.Hose Connection [Optional]
Attach rubber or plastic hose [supplied by
owner] to hose adapter [AVTEC optional
feature] and route to open floor drain.
2.Refrigeration Drain
The drain may be connected if desired, in
the same manner as the hot food well
drain or a bucket may be used in lieu of a
drain connection. The bucket should be
placed under the drain shut-off valve,
located behind the end doors.
[connection from above].
[hose] assembly is
female quick-disconnect
Insert quick-
The
1
1
OPERATING INSTRUCTIONS
II. STANDARD CONTROLS
A.Modular Electrical Distribution System
The Tray-Trac has an electrical service
terminal box which is connected to the
main incoming electrical service. From
this point, power supply is provided to
each Modular Electrical Distribution
System [MR0E] running the length of each
side of the Tray-Trac. Each MR0E unit is
a linear panel board, with a main service
disconnect breaker, main system cable
bus and link plates containing a point-ofuse circuit breaker and either receptacle,
switch or internal connection. These link
plates can be moved to any location on
the system, or new plates can be added,
as long as the total kilowatt capacity
[ampacity] of each MR0E unit is not
exceeded.
B.Start/Stop Station
The unit is equipped with one or more pairs
of push buttons which are used to start and
stop the carousel motor. Depressing any of
the STOP buttons will stop the carousel
motor. These switches are intended to start
and stop the carousel at the beginning and
end of the serving period or whenever the
tray carriers will not be in use for an
extended period of time.
C.Speed Control
The unit is supplied with a variable speed
control unit located on the unload end
[inside
STOP/START Station, accessible through
the base cabinet door or access panel.
Trays must be timed manually and
adjustment made on the speed control dial.
See separate instructions for more detailed
information. Max speed of
minute.
III.ACCESSORIES AND CONTROLS
The following optional features may or may
not be supplied. Check drawing and
specifications to determine which features
are included in your systems.
A.Momentary Foot Stop Switch
The Tray-Trac is equipped with a two position
terminal within the Modular Distribution
the Tray-Trac] behind the
10 trays per
2
System at tray unload end. The optional
foot-operated momentary stop switch can be
mounted at this location. Depressing the foot
switch will cause the carousel motor to stop
and it will remain stopped as long as the
switch is depressed. When the operator’s
foot is removed, the carousel will begin
rotating again.
B.Fluorescent Work Lights
Fluorescent work lights may be supplied
beneath the carousel and/or under the
overshelf. The overshelf lights incorporate a
diffuser panel that is integral to the fixture to
reduce glare, protect the bulb an equalize
light distribution. The carousel work lights
use a separate prismatic clear plastic sheet
to protect the bulb and aid in light diffusion.
To replace the carousel bulb, slide the
diffuser panel upward in its slot, and allow the
back edge to drop down and out. The work
lights are operated by a switch that is usually
located alongside the carousel start/stop
switch. Power for the work lights is drawn
from one of the Modular Electrical
Distribution Systems. Three foot fixtures
require #F30-T8 Slimline Lamps, 18” fixtures
require #F15-T8 Slimline Lamps.
C.Hot Food Wells
Heavy-duty rectangular food wells can be
provided with or without drains. Wells are
able to accommodate a standard 12” x 20”
#200 pan up to six inches deep and are
suitable for either wet or dry operation. The
warming element is controlled by an infinite
switch control with a positive-OFF position.
Each food warmer has a separate control A
red signal light indicates a power-ON
condition. Add water to warmer BEFORE
preheating.
DRY, PRE-HEATED WARMER MAY
DAMAGE THE UNIT.
preheating, add hot water, place empty pan
in well, then cover well. Preheating varies
from 15-30 minutes.
NOTE: Hot food wells are warranted
directly by the manufacturer; refer to
separate warranty and owner’s
information.
Some hot food wells may be supplied with a
strainer and drain manifold. This manifold is
POURING WATER INTO A
For most efficient
equipped with a ¼ turn ball valve for flushing
and threaded caps at each end for easy
periodic rodding. At least 1” of water should
be in all wells prior to each meal assembly.
The most common method for putting water
into the hot food wells is to back feed through
the drain manifold. By closing the drain
manifold shut-off valve [located in the base
near the end doors] and filling one hot food
well, the water will back up into the other hot
food wells. Hot food wells without drains
must be filled individually and drained with a
cup and sponge.
D.Cold Tops and Cold Pans
Cold Tops [raised cooling surfaces] and Cold
Pans
available for full and half base Tray-Tracs.
The circuits for these items are protected by
breakers in the Modular Distribution Systems.
THESE BREAKERS SHOULD NOT BE
USED TO TURN THE UNITS ON AND OFF.
Switches have been provided beside each
breaker for turning these items on and off.
Units should be turned on approximately
thirty minutes prior to use and left on until the
end of the day.
NOTE: Cold tops and cold pans may or may
not frost, depending on humidity and ambient
atmospheric conditions.
The refrigerated surfaces are supplied with a
removable strainer and drain, which is routed
to one end of the Tray-Trac. This piping is
equipped with a 1/4-turn shut off valve for
flushing and threaded caps for periodic
rodding. To prevent back-up into drain
gutter, the drain should be flushed daily into
[recessed cooling surfaces] are
the open floor drain or bucket, and rodded
periodically.
E.Checker Audio Call System
To aid in communications between the
personnel, a Checker Audio Call Station can
be supplied. Power is supplied from a circuit
breaker connection plate in the Modular
Distribution Panel along the side of the unit.
To turn the system on, make sure that the
circuit breaker is on. Depress the ON/OFF
switch and the Power Indicator LED will
illuminate. If only one microphone is used,
adjust volume by turning the know labeled
“INPUT 1” until the desired level is obtained.
If two microphones are used, adjust the
volume of one microphone using the “INPUT
1” knob and adjust the volume of the second
microphone using the “INPUT 2” knob. The
“PROGRAM” knob is not used in Tray-Trac
applications. When the Checker Audio Call
Station will not be in use for an extended
period of time, turn the unit OFF using power
on/off switch.
After adjusting the amplifier, you are ready to
use the Checker Audio Call Station. To use
the system, hold the button on the side of the
microphone IN while speaking.
microphone is ON only while the button is
held IN.
microphone is mounted on an 18” long
adjustable, flexible gooseneck.
adjustments, consult the amplifier and
microphone operations manual.]
F.Timer Programmer [Seven Day, 24-Hour]
The timer programmer is used to
automatically control the ON/OFF of integral
and ancilliary equipment connected to the
Tray-Trac unit, especially heated bases.
Each Modular Electrical Distribution System
[MR0E] is connected separately thru a
bypass switch to the timer/programmer.
Either MR0E unit may be ON or OFF the
program. The timer/programmer and bypass
switches are located as shown on the
drawing. Refer to separate instructions for
programming.
For your convenience, the
[For further
The
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