Prince Castle DCFT-JB Service Manual

Operation
Manual

Dual Continuous Feed Toaster

DCFT-JB

Product Identification

Conveyors

Bun Feeder

Platen

Adjustment

Knobs

Control Panel

Platen

On/Off Switch

LIMITED WARRANTY

This product is warranted to be free from defects in material and/
or workmanship for a period of one (1) year from date of original
installation, not to exceed 18 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:

• Use of any non-genuine Prince Castle parts voids this
warranty and all work must be performed by an authorized
Prince Castle Service Agent.

• All labor shall be performed during regular work hours.
Overtime premium will not be covered.

• Travel charges are limited to 100 miles (200 kilometers) round
trip, 2 hours travel time, one trip per repair.

• Damage caused by carelessness, neglect, and/or abuse (e.g.,
using wrong current, dropping, tampering with or altering
electrical components, or improper cleaning) is not covered.

• Equipment damaged in shipment, by fire, flood or an act of
God is not covered.

• Damage to non-stick coated surfaces is not covered by this
warranty.

LCD

Display

PRINCE CASTLE

Logo Button

UP and DOWN

Scroll Buttons

INFORMATION

TABLE OF CONTENTS

Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Management Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Programming Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Daily Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Exploded Views and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

MODE
Button

Button

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355 East Kehoe Blvd. • Carol Stream, IL 60188 USA

Telephone: [phone] • Toll Free: 1-800-PCASTLE

Fax: [phone] • www.princecastle.com

526-502 Rev C_EN Printed in USA 06/12 © 2012

Dual Continuous Feed Toaster
DCFT-JB

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Safety Information

WARNING

Indicates information important to the proper operation of
the unit. Failure to observe may result in damage to the
equipment and/or severe bodily injury or death.

CAUTION

Indicates information important to the operation of the unit.
Failure to observe may result in damage to the equipment.

Unpack and inspect. Remove the unit from the

1

carton and inspect for signs of damage. If there is
damage to the unit:

• Notify the carrier within 24 hours of delivery.

• Save carton and packaging materials for inspection
purposes.

• Contact your local dealer, or if purchased directly,
the Prince Castle Sales Department at
1-800-722-7853 or 630-462-8800 to arrange for a
replacement unit.

Prince Castle 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.

208/240V, 2700/3600W, 50/60 Hz

Installation

6

Important

Electrical Specifications

Install release
sheets. Place

®

Teflon

release
sheets over the
platen.

Verify parts. Verify that all parts have been received:

2

• Dual Continuous Feed Toaster with two conveyors.

• Release Sheet Kit.

• Conveyor adjustment tool.

Place toaster on flat surface. Remove blue and/or

3

white protective covering.

Remove packing. Remove the cardboard spacer

4

holding the conveyors up for shipping.

Open conveyors.

5

Lift each conveyor
up and out. Set
conveyors down
and remove all
cardboard and
styrofoam from the
conveyors and from
the interior of the
unit.

Close conveyors.

7

Lift one conveyor,
lining up its top
mounting guides
with the top
conveyor mounting
pins on the unit.
Slide the conveyor
in and down until it
is securely in
place. Repeat with
the other conveyor.

Plug unit in. Plug

8

unit into a grounded
receptacle with a
matching plug
configuration.

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Dual Continuous Feed Toaster

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Operation

Turn unit ON. Turn the

1

On/Off switch located
opposite the display
panel to ON. The
Prince Castle DCFT
screen will appear in
the LCD display for
3 seconds.

Wait through Warm-

2

Up. During warm-up,

the LCD display will
read “STATUS” and
“WARMING…”.
Warm-Up time is about
10-15 minutes.

3

BURN/ELECTRICAL SHOCK HAZARD! Platen
sections are HOT and can cause severe burns or
severe shock. Keep hands and objects out of the
toaster unit! Failure to exercise caution may result
in serious injury! Turn the unit off, unplug it and let
it cool down completely before touching or
working on internal apparatus.

WARNING

warming...

status

Observe conveyor. If conveyor motion is not smooth

4

or is not moving, call for service.

View temperatures, if

5

desired. Pressing the

INFORMATION button
once will display the
left and right platen
actual temperatures.
Pressing a second time
will return the LCD
display to the READY
screen.

Choose the platen

6

adjustments. Dial the

two front platen
adjustment knobs for
the product part
(Regular Crown, etc.)
that you will be toasting
in the front of the unit.
Dial the two rear platen
adjustment knobs for
the product part
(Regular Heel, etc.)
that you will be toasting
in the rear of the unit.

Rear Platen
Adjustment

Knob

Front Platen

Adjustment

Knob

status

ready

Watch for READY
status. When ready

temperature is reached,
the LCD display will
read “STATUS” and
“READY”.

526-502 Rev C_EN 3 Printed in USA 06/12 © 2012

status

ready

Begin continuous

7

feeding. Feed

product into top of
DCFT, sending the
correct product parts
down the front and
rear of the unit. The
sides to be toasted
should face the
platen. Toasted
product will exit
at the base of
the DCFT.

Dual Continuous Feed Toaster
DCFT-JB

Management Programming

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Enter program screens.

1

Press and hold the PRINCE
CASTLE logo button for 6
seconds. The
PROGRAMMING VERSION
screen will appear in the
LCD display for 10 seconds.

From the PROGRAMMING
VERSION screen, you may:

A. Press the DOWN scroll

button once to choose
Fahrenheit or Celsius.

B. Press the DOWN scroll

button twice to adjust
temperature.

C. Press the DOWN scroll button three times to

change language.

D. Press the PRINCE CASTLE logo button or leave

the controls inactive for 10 seconds to exit
programming.

Choose Fahrenheit or

2

Celsius. From the

PROGRAMMING VERSION
screen, press the DOWN
scroll button once. From the
SELECT F/C screen that
appears, press the MODE
button.

A. From the SET F/C

screen that appears, use
the UP and DOWN scroll
buttons to select TEMP =
F (Fahrenheit) or TEMP
= C (Celsius).

Status

ready

select

f/c

set f/c
temp c

Adjust set point

3

temperatures. From the

SELECT F/C screen, press
the DOWN scroll button.
From the SELECT PLATEN
TEMPERATURES screen,
press the mode button.

A. From the SET RIGHT

screen that appears,
adjust the right platen set
point temperature using
the UP and DOWN scroll
buttons.

B. Accept the new right

platen setting by pressing
the MODE button, which
will bring the SET LEFT
screen. NOTE: To cancel

without accepting the
new setting, press the
PRINCE CASTLE logo
button to return to the
SELECT PLATEN
TEMPERATURES
screen.

C. From the SET LEFT

screen, adjust the left
platen set point
temperature using the
UP and DOWN scroll
buttons.

select platen

temperature

set right

temp 550f

set right

temp 549f

set left

temp 550f

B. Accept the new scale by

pressing the MODE
button to return to the
SELECT F/C screen.

NOTE: To return without
accepting the new
setting, press the
PRINCE CASTLE logo
button.

set f/c
temp F

D. Accept the new left

platen setting by
pressing the MODE
button to return to the
SELECT PLATEN
TEMPERATURES
screen. NOTE: To return

without accepting the

set left

temp 551f

new setting, press the
PRINCE CASTLE logo
button.

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Dual Continuous Feed Toaster

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Management Programming (continued)

Change language. From

4

the SELECT PLATEN
TEMPERATURE screen,
press the DOWN scroll
button. From the SELECT
LANGUAGE screen, press
the MODE button.

A. From the LANGUAGE

screen that appears, use
the UP and DOWN scroll
buttons to select a
different language.

select

language

language

english

Exit programming.

5

Press the PRINCE
CASTLE logo button
from the SELECT F/
C, SELECT PLATEN
TEMPERATURE or
SELECT LANGUAGE
screen or leave the
controls inactive for
10 seconds.

Temperature Factory

Presets

Right Side of Platen 500°F
Left Side of Platen 500°F

select

New Setting

f/c

B. Accept the new language

by pressing the MODE
button to return to the
SELECT LANGUAGE
screen. NOTE: To return

without accepting the
new setting, press the
PRINCE CASTLE logo
button.

language

french

526-502 Rev C_EN 5 Printed in USA 06/12 © 2012

Dual Continuous Feed Toaster
DCFT-JB

Press

(6 secs)

programming

version

1.00

Programming Diagram

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Press

Press

or

select

f/c

or

select platen
temperatures

Press or

select

language

Press or

Press Press

set f/c
temp f

Press to change

to F or C

Press Press Press

Press Press

set right

temp 550F

Press to change

temp

language

english

set left

temp 550F

Press to change

temp

Press or

language

spanish

Press

Press or

Press or

language

french

Press

Press or

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Daily Planned Maintenance

WARNING

BURN/ELECTRICAL SHOCK HAZARD! Platen sections
are HOT and can cause severe burns or severe shock.
Keep hands and objects out of the toaster unit! Failure
to exercise caution may result in serious injury! Turn
the unit off, unplug it and let it cool down completely
before touching or working on internal apparatus.

WARNING

If the supply cord is damaged, it must be replaced by
the manufacturer, its service agent, or similarly
qualified person to avoid a hazard.

Open conveyors.

4

Lift each conveyor
up, out and set
down in open
position.

Dual Continuous Feed Toaster

DCFT-JB

CAUTION

Do not immerse toaster in water. Do not clean with a
water hose or jet spray. Do not use abrasive cleaners,
pads or tools on the platen or the release sheet. Failure
to exercise caution will result in damage to the unit and
will not be covered by warranty.

Gather cleaning materials. You will need a clean,

1

damp cloth, soft bristle brush, neoprene gloves,
lukewarm soap and water, and non-abrasive cleaner.

Turn DCFT OFF. Turn

2

the On/Off switch
located opposite the
display panel to OFF.

3

Unplug and let
cool. Allow platen to

cool for 60 minutes
before cleaning.

Remove the

5

release sheets.

Lay the release
sheets on a flat
surface.

Clean the

6

conveyors.

Put on
neoprene
gloves. Wipe
the conveyors
with a damp
cloth. Use a
soft bristle
brush as
necessary.

526-502 Rev C_EN 7 Printed in USA 06/12 © 2012

Dual Continuous Feed Toaster
DCFT-JB

Daily Planned Maintenance (continued)

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Clean the release sheets. Dampen a clean cloth

7

with lukewarm soap and water. Wipe down both
sides of the release sheets, making sure all built-up
sugar is removed. Allow to air dry. NOTE: Rotate

sheets daily for longer life. Depending on volume of
product toasted, sheets should be replaced every
4 to 6 weeks.

Clean the platen

8

surface. Use a

damp cloth to
remove any built­up sugar on the
surface.

9

10

Clean outside
of the DCFT.

Dampen a
clean cloth
with lukewarm
soap and
water. Wipe
down the
outside of the
entire DCFT.
Wipe down the
entire DCFT
again with a
fresh clean,
sanitized
towel.

Reassemble
the unit.

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Dual Continuous Feed Toaster

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Troubleshooting

WARNING

BURN/ELECTRICAL SHOCK HAZARD! Platen sections are HOT and can cause severe burns or severe shock.

Keep hands and objects out of the toaster unit! Failure to exercise caution may result in serious injury!

Turn the unit off, unplug it and let it cool down completely before touching or working on internal apparatus.

PROBLEM POSSIBLE CAUSE SOLUTION

Unit will not heat up. No power to unit. Ensure power cord is connected to proper

Inoperable power cord. Replace power cord.
Loose connection on power switch. Tighten power switch connections.
Inoperable power switch. Replace power switch.
High limit switch tripped. Reset high limit switch.
Inoperable thermostat. Replace thermostat.
Inoperable platen. Replace platen.

Unit heats up, but the conveyor does not run. Loose motor switch connection. Tighten motor switch connection.

Inoperable motor. Replace motor.
Inoperable motor switch. Replace motor switch.
Stripped drive gear. Replace drive gear.
Loose chain sprockets. Adjust and tighten sprockets.

Unit under- and over-heats (does not
respond to programming).

Buns under or over done. Check platen adjustment. (See Operation.) Move platen adjustment knobs to the correct

Conveyor motion appears jerky or a
“skipping” sound can be heard.

Check temperature setting. Adjust temperature set point setting. See

Inoperable thermostat. Replace thermostat.

Check platen temperature. (From READY
screen, pressing the INFORMATION button
once will display the left and right platen
actual temperatures.)

Gears may be out of alignment. Call for service.

receptacle.

Management Programming.

product part setting.
Adjust temperature set point setting. See

Management Programming.

526-502 Rev C_EN 9 Printed in USA 06/12 © 2012

Dual Continuous Feed Toaster
DCFT-JB

Exploded View and Parts List

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No. Part No. Description

1 526-073S Membrane Switch w/Overlay
2 526-021S Display Board
3 526-201S Main Board
4 85-144-24S Power Supply Board
5 526-025S Motor
6 526-023S Fan (qty of 2)
7 526-032S Handle (qty of 2)
8 78-233S Power Switch
9 526-362S Platen
10 65-058S SS Relay 50A
11 65-064S Power Relay
12 77-090S Terminal Block
13

525-022S

14

525-024S

15 526-295S Gear (qty of 2)

Crown Conveyor
Heel Conveyor

17

6

7

10
12

No. Part No. Description

16 72-446S Power Cord
17 526-221S Knobs (qty of 2)
18 526-279S Teflon Sheets
19 526-281S Hi Limit
20 77-092-03S Terminal Block
21 526-185S Minor Side Overlay
22 526-617S In-Feed
23 526-606S Back Plate

* 526-022S Probe
* 526-184S Major Side Overlay
* 526-392S Idler Sprocket (qty of 2)
* 526-081S Drive Sprocket (qty of 3)
* 526-614S Rope Heater, Landing Zone

* Not Shown

18

14

9

2

5

11

6

19

1

16

17

15

3

13

20

4

21

7

8

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Dual Continuous Feed Toaster

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Wiring Diagram

1

RIGHT HEATER

LEFT HEATER

RIGHT TEMP PROBE

LEFT TEMP PROBE

YEL

BLK

BLU

WHT/GRN

BRN

WHT/BLK

WHT/RED

WHT/BRN

16

WHT/VIO

RED

BLK

MEMBR SWIT

WIRING DIAGRAM

526-393 REV --

ORG

LCD DISPLAY

WHT/VIO

RED

DAUGHTER BD.

BLK

1

J3

1

J2

MAIN PCB

7

J9

J10

J8

1

J12

1 1 1 1 11

1

ORG

J1 J26 J25 J28 J27 J17 J11

BLK

GRY

VIO

BLU

BLU

YEL

WHT/GRN

BLK

BLU

BRN

WHT/BLK

ORG

WHT/RED

WHT/BRN

J16

SWITCH

THERMAL

WHT/BLK
YEL
WHT/BLK
BRN

RED
WHT/YEL
WHT/ORG
WHT/BRN
BLK
YEL
ORG
BRN

11 1

1

J6 J3 J7J14 J15

1

BLU

BLU

MOTOR

8

J4

4

PWR CORD

6

3

PWR SWIT

2/T1

BRN

BLU

4

5

BRN

1

2

AC SSR 1 AC SSR 2

L 1

1/L1

208-240VAC

BRN

BLU

GRN/YEL

GND

LEFT-SIDE

FAN

WHT/BLK

GRY

BLK

FAN

RIGHT-SIDE

WHT/BLK

(+)

2/T1

VIO

SSR 1

YEL

(-)

HEATER 1

1/L1

BRN

BRN

BRN

BRN

(-)

(-)

(+)

(+)

SSR 2

HEATER 2

1/L1

2/T1

2/T1

1/L1

BRN

ORG

1

WHT/BRN

POWER SUPPLY

1

BRN

BLU

WHT/BLU

L 2

1/L1 2/T12/T11/L1

BLU

BLU

BLU

526-502 Rev C_EN 11 Printed in USA 06/12 © 2012