Frymaster, a member of the Commercial Food Equipment Service Association, recommends
using CFESA Certified Technicians.
24-Hour Service Hotline 1-800-551-8633
JANUARY 2004
*8195993*
Page 2
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.
Page 3
CT16 SERIES TOASTER
SERVICE AND PARTS MANUAL
CHAPTER 1: SERVICE PROCEDURES
Upper
Compression
Adjustment
Knobs
LED
DISPLAY
RAISE
SETPOINT
BUTTON
ON/OFF
BUTTON
REDY
LOWER
SETPOINT
BUTTON
DISPLAY
TEMPERATURE
BUTTON
Lower
Compression
Adjustment
Knobs
1.1CT16 Toaster Functional Description
Bun Guide for Heel
and Crown Slots
Heated Holding Tray
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.
1.2Power Requirements
ALL ELECTRICALLY OPERATED APPLIANCES MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES, OR
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
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
1-1
Page 4
1.3Replacing 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
Page 5
Step 10c - Remove
these four hex head
screws and two nuts.
Step 10d - Remove last two screws
and pull conveyor away from housing.
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
Page 6
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
Page 7
Platen Tray Brace
Heater Probe
NOTE: Probe
and high limit
wires must be
routed through
this bushing as
shown by large
arrow.
High Limit
Plug
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
Page 8
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
Page 9
1.4Technician Troubleshooting
PROBLEMPROBABLE CAUSESCORRECTIVE ACTION
A. Failed transformer.
Display remains blank
when unit turned on.
B. Failed computer.
C. Failed cover interlock switch or failed
high limit.
A. Failed motor.A. If platen is heating, replace motor.
Computer display is on, but
motor is not running
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).
B. Broken/loose wire between computer and
latch relay or failed latch relay.
A. Toaster improperly configured for power
supply.
A. Improper power-supply.
B. Failed temperature probe.
Platen heats, but unit does
not reach setpoint.
C. Failed computer.
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.
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
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.
B. Check for 12VDC on Pins 6 & 7 of
computer. If present and wiring is intact,
replace latch relay. If not present, replace
computer.
A. Check data plate for voltage rating, and
verify that power supply and toaster
match.
A. Verify that the power supply is 20 amp
single-phase 200, 208 or 240VAC
(depending upon model).
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.
C. 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 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
Page 10
PROBLEMPROBABLE CAUSESCORRECTIVE ACTION
A. Check for 12VDC on computer pins 6 &
7. If NOT present AND motor is running,
replace computer. Check for 5VDC on
A. Failed computer.
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.
B. Broken/loose wire between computer and
latch relay, or failed latch relay.
B. Check for 12VDC on computer pins 6 &
7. If present and wiring is intact, replace
latch relay.
C. Determine temperature of platen then
measure main heater probe resistance at
Platen does not heat, but
computer display is on.
C. Failed main heater probe.
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.
D. Check for 5VDC on terminals 3 & 4 of
D. Broken/loose wire between computer and
main heater relay, or failed main heater
relay.
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.
E. Check for 5VDC on terminals 3 & 4 of
main heater relay and for line voltage on
E. Failed platen.
terminal 2 of main heater relay and
terminal 4 of latch relay. If expected
voltage is present at all three points,
replace the platen.
Probe Resistance Chart
For use with CT16 Series toasters manufactured with Minco Thermistor probes only.
NOTE: These diagrams depict wiring as of the date of manual publication. They may not
reflect design changes made to the equipment after publication. Always refer to the wiring
diagram affixed to the unit when actually troubleshooting or servicing this equipment.
NON-CE TOASTERS
1-9
Page 12
CE AND AUSTRALIAN TOASTERS
1-10
Page 13
1.6Schematic
LINE VOLTAGE
LINE FILTER (CE AND AUSTRALIAN TOASTERS ONLY)
Transformer
COM NO
12Volt
Secondary
Cover
Interloc
k
High
Limit
98
3
6
COMPUTER
5
Main
Heater
Probe
4
Resistor
12
Latch
Relay
6
8
3
4
2
Main
Heater
Relay
Main
Heater
7
1
0
2
4
1
Cartridge
Heater
Drive Motor
M
Fan
F
1-11
Page 14
THIS PAGE INTENTIONALLY LEFT BLANK.
Page 15
CT16 SERIES TOASTER
SERVICE AND PARTS MANUAL
CHAPTER 2: PARTS LIST
2.1Introduction
CT16 Toasters manufactured for use in the European Union (CE) and those manufactured for use
elsewhere are identical in most respects, but there are some important differences. The paragraphs
that follow summarize the differences and provide a list of the parts that are unique to each model.
The most significant differences are in the electronic components. Units built for the CE and Australian
markets have a 50 Hz motor; all others have a 60 Hz motor. Non-CE and CE/Australian units also use
different transformers, and CE/Australian units have a line filter built into the electrical power supply
system. The line filter and cover are attached to the rear of the cabinet.
Because of the difference in the power cycle frequency (50 Hz vs. 60 Hz), CE and Australian units are
equipped with 10-tooth drive pulleys and a 28-Tooth motor pulley. Standard units have 17-tooth drive
pulleys and an 18-tooth motor pulley. The different pulleys on the CE and Australian units maintain the
correct belt speed even though the RPM of the motor at 50 Hz is slightly slower than that of the motor
at 60 Hz.
The table below identifies the components that are unique to each configuration.
Components Unique to CE andAustralian UnitsComponents Unique to Non-CE Units
P/NDescriptionP/NDescription
807-2191Transformer (208-240V/12V)807-0979Transformer (208-240V/12V)
807-0910Transformer Fuse, 250V/3AN/ANot used.
106-0781Transformer and Bracket AssemblyN/ANot used.
807-3472Line FilterN/ANot used.
824-0896Line Filter CoverN/ANot used.
106-2143Tensioner Assembly, Drive Belt106-2723Tensioner Assembly, Drive Belt
810-230028-Tooth Motor Driven Pulley810-256518-Tooth Motor Driven Pulley
810-230110-Tooth Dual Belt Drive Pulley810-256617-Tooth Dual Belt Drive Pulley
810-233210-Tooth Toasting Belt Drive Pulley810-256417-Tooth Toasting Belt Drive Pulley
The illustrations in the parts list that follows also identify the CE/Australian and Non-CE components.
2-1
Page 16
2.2Cabinetry
16
17
18
1
27
13
11
27
12
28
29
8
9
10
2423
30
6
29
7
29
1920
21
14
16
2226
2
3
4
30
25
5
2-2
Page 17
ITEMPART #COMPONENT
1106-2720SPBack Cover Assembly
2824-1117Tray Assembly, Toast
3816-0573Insulation, Toast Tray
4200-4270Bottom, Toaster
5816-0589Seal, Toaster Base
6823-3988Housing, Component
7210-5311Bracket, Lower Hinge
8823-2941Bracket, Upper Hinge
9210-3434Cover, Air Inlet
10200-2877Brace, Component Housing
11210-2876Cover, Component Housing
12810-2331Knob, Compression Adjustment
13106-0785SPCover, Line Filter (used on CE and Australian units only)
14810-2549Guide, Bread (Wireform Feeder)
15106-2158Cover Assembly, Toaster (includes Items 16-21)
16823-3656Cover (does not include Items 17-21)
17810-0066Magnet
18810-1683Handle, Cover
19910-9458Reinforcement, Cover Side
20809-0184Washer, #10 Lock
21809-0107Screw, 8-32 x ⅜-inch Slotted Round Head
22809-0104Screw, 8-32 x ½-inch Slotted Truss Head
23809-0112Screw, 8-32 x 1 ¼-inch Slotted Truss Head
24809-0247Nut, 8-32 Hex
25809-0434Screw, #10 x ⅜-inch Hex Washer Head
26809-0448Clip, Tinnerman
27826-1330Screw, 10-32 x ⅜-inch Slotted Truss Head (Pkg. of 25)
28826-1374Screw, #10 x ½-inch Hex Head (Pkg. of 25)
29826-1379Screw, #10 x ½-inch Philips Truss Head (Pkg. of 10)
30826-1389Screw, ¼-20 x ¾-inch Hex Head (Pkg. of 10)
*810-1712Clip, Adhesive-backed Wire Routing
* Not illustrated
2-3
Page 18
2.3Conveyor Assembly, Dual Belt
3
19
24
12
21
17
18
5
22
18
15
8
1
9
7
10
5
23
11
20
4
17
16
7
13
2
6
14
2-4
Page 19
ITEMPART #COMPONENT
1806-9200Roller Assembly, Dual Belt Idler
2806-9318Roller Assembly, Dual Belt Drive
3810-2303Washer, Teflon Crumb
4809-0132Screw, ¼-20 x ¾-inch Slotted Pan Head
5826-1374Screw, #10 x ½-inch Hex Head (Pkg. of 25)
6809-0647E-Ring
7809-0745Washer, ¼-inch Flat
8810-1672Spring, Compression Plate
9810-1718Shaft, Short Dual Belt Roller
10810-1776Pin, VT Cotter
11810-1802Bushing, Tray Stabilizer Latch Support
12810-1818Spring, 3.00-inch Long, 4.6 Lbs./Inch
13810-2305Bushing
14816-0389Belt, Dual Conveyor
15823-2719Plate Assembly, VT Right Pressure
16823-3578Plate Assembly, VT Left Pressure
17823-2722Cam Assembly, VT Long
18823-2723Cam Assembly, VT Short
19823-2798Cover Assembly, VT Spring
20823-2838Latch Assembly, VT Tray
21823-3989Tray Assembly, Dual Belt
22900-8155Bracket, Guide Rod
23910-8254Brace, Dual Belt Tray
24910-8512Bracket, Spring Guide Receiver
25210-4245Bracket, Left Center Support
26210-4246Bracket, Right Center Support
2-5
Page 20
2.4Conveyor Assembly, Toasting
6
28
3
11
1013
27
24
14
1
18
19
22
12
20
7
5
28 29 30
31
25
2
15
8
17
4
16
2-6
Page 21
ITEMPART #COMPONENT
1106-2123SPTray with Grommet, VT Platen
2210-0318Crumb Shield, Toasting Conveyor
3806-9195Roller, VT Toasting Belt Idler
4806-9196SPPlaten Assembly, VT
5806-9199Roller, VT Toasting Belt Drive
6810-2303Washer, Teflon Crumb
7809-0266Screw, #10 x ½-inch Philips Truss Head
8809-0647E-Ring
22810-1722Grommet, .5-inch I.D. x 1.05-inch O.D. (Integral component of Item 1)
23810-2013Roller, VT Drive (Integral component of Item 3)
24810-1810Bushing, Teflon (Integral component of Item 3)
25807-3037Thermostat, High-Limit (Integral component of Item 4)
26910-8637Spacer, High-Limit Thermostat (Integral component of Item 4)
27809-0729Capscrew, 6-32 x ¼-inch Socket Head (Integral component of Item 4)
28807-3247Probe, Heater (Integral component of Item 4)
29910-8757Retainer, Heater Probe (Integral component of Item 4)
30826-1330Screw, 10-32 x ⅜-inch Slotted Truss Head (Integral component of Item 4)
31810-1658Platen, 5000W (Integral component of Item 4)
* Obscured by Item 1. See Item 24 on Page 5 for illustration.
2-7
Page 22
2.5Electronic Components
15
14
7
6
5
4
3
2
1
8
10
13
9
12
2-8
11
Page 23
ITEMPART #COMPONENT
1807-3213Relay, Solid State 5A 3/16 Control Terminals
2807-3021Relay, 30A 12VDC DPST NO
3826-1562Relay, Solid State 40A 280V SPST NO
4106-0781SPTransformer and Bracket Assembly, CE and Australian
*807-0910Fuse, 250V 3A (fuse for CE/Australian transformer)
9807-3064Switch, Cover Interlock
10806-9796Resistor Assembly, Holding Tray
11807-3243Cordset, Standard Twist-Lock
12807-3198Cordset, Hooded Twist-Lock
13807-3242Cordset, Pin and Sleeve
14807-3529Cordset, CE VT
15807-3850Cordset, Australian VT
*Not illustrated.
2-9
Page 24
2.6Motor, Drive Train, and Fan Components
See Page 6
3
4
See Page 4
8
7
2
9
1
5
ITEMPART #COMPONENT
1Motor Assembly, 50/60 Hz
106-3052200-208V VT Drive
106-2841220-250V VT Drive
2810-2302Drive Belt
3106-2128Bracket Assembly, VT Idler Pulley
4826-1368Nut, ¼-20 Serrated Flange (Pkg. of 10)
5Pulley, Motor Driven
810-256518-Tooth (Non-CE
810-270421-Tooth (CE and Australian)
6106-2723Tensioner Assembly, Drive Belt
7810-2566Pulley, 17-Tooth Dual Belt Drive
8810-2564Pulley, 17-Tooth Toasting Belt Drive
9106-2703Fan Assembly, VT Motor Cooling
6
2-10
Page 25
THIS PAGE INTENTIONALLY LEFT BLANK.
Page 26
Frymaster, L.L.C., 8700 Line Avenue, PO Box 51000, Shreveport, Louisiana 71135-1000
Shipping Address: 8700 Line Avenue, Shreveport, Louisiana 71106
TEL 1-318-865-1711FAX (Parts) 1-318-688-2200FAX (Tech Support) 1-318-219-7135
PRINTED IN THE UNITED STATES
SERVICE HOTLINE
1-800-551-8633
819-5993
JANUARY 2004
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