Service Manual KT COUNTER
Contents
1. A WARNING Before performing any service that involves electrical connection or disconnection and or exposure to electrical components always follow the Electrical LOCKOUT TAGOUT Procedure Disconnect all circuits Failure to comply can cause property damage injury or death The Electrical LOCKOUT TAGOUT Procedure is used to protect personnel working on an electrical appliance Before performing any maintenance or service that reguires exposure to electrical components follow these steps 1 In KT Load Center place appliance to be replaced or repaired circuit breaker in the OFF position 2 Place a lock or other device on Load Center door to prevent someone from placing circuit breaker ON 3 Place a tag on the Load Center door to indicate that appliance has been disconnected for service and power should not be restored until tag is removed by maintenance personnel HOT FOOD TABLE AND DRY CHANNEL WARMERS Toggle Switches There are two Toggle Switches mounted on the Hot Food Table These switches control the APW griddle and the Hatco Taco tower Figure 1 Location of Toggle Switches 1 Follow proper LOCKOUT TAGOUT procedures 2 Remove the switch plate 3 Remove the screws securing the failed switch 4 Pull the switch forward out of the box enough to access the electrical connections being careful not to place stress on the wires 5 Loosenthe screws securing the2. 3 Evacuate coolant following procedures in the RECHARGING REFRIGERATION SYSTEM section of this manual Disconnect the coolant tubing Lift Top Cold Pan Assembly out of the KT Counter Install new Top Cold Pan Assembly M FR Braze coolant lines from new Top Cold Pan to compressor lines 8 Chargethe cooling system Refer to the RECHARGING REFRIGERATION SYSTEM section of this manual Thermostat Cold Pan ON OFF Switch Cold Pan Digital Thermostat Figure 9 Location of Cold Pan Thermostat The Top Cold Pan Thermostat is located in the compressor compartment behind the louvered vent The Top Cold Pan Compressor is located next to the refrigerator doors on the side of the KT Counter that does NOT have the refrigerator temperature display 1 Place the Main Power ON OFF switch in the OFF position Perform proper Lockout Tagout procedures Remove the louvered vent Tag and disconnect thermostat wiring Disconnect the capillary tube Remove thermostat from mounting bracket ov oe pm S Install new thermostat being careful notto kink capillary tube while reconnecting it oo Referring to tags reconnect wires 9 Set the thermostat according to Subway guidelines 10 Reattach front panel and air filters 11 Restore power to the KT Counter 12 Allow the Top Cold Pan to cool for approximately twenty minutes before performing a temperature check on each channel 13 Adjust Thermostat as nee
3. injury or death A WARNING Appliances equipped with a flexible electric supply cord are provided with a three prong grounding plug It is imperative that this plug be connected into a properly grounded three prong receptacle Failure to comply with this procedure can cause property damage injury or death A WARNING If the receptacle is not the proper grounding type contact an electrician Do not remove the grounding prong from the plug Failure to comply with this procedure can cause property damage injury or death A WARNING Before performing any service that involves electrical connection or disconnection and or exposure to electrical components always perform the Electrical LOCKOUT TAGOUT Procedure Disconnect all circuits Failure to comply with this procedure can cause property damage injury or death A WARNING Before removing any sheet metal panels or servicing this equipment always perform the Electrical LOCKOUT TAGOUT Procedure Be sure all circuits are disconnected Failure to comply with this procedure can cause property damage injury or death AWARNING Do not operate this equipment without properly placing and securing all covers and access panels Failure to comply with this procedure can cause property damage injury or death A WARNING Do not use or store gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance Failure to
4. System oegegoEe eege p a kontao o e 11 RBG Door Gaskets vivsisscssscessaseear bine oken nren a E ea agin tana kodeku yo ad Ehe 11 RBC Door Adjustiment so vsscodteeanedsavsceasia cosiecdateabesehenreitenr directa landaaediear 11 LOAD CENTER Qu uuu us u Qua a tia ubaspa 11 Circuit BreakeriReplaceiment ws uu a uu uum aaa aa mien R z v Ancients 12 RECHARGING REFRIGERATION SYSTEM 1 1 11 1 4 4 44 4 4 4 4 2022220eeeee ee e ee etera ee ee ee eo aaa 0000 12 Re E 12 Duke Service Bulletin Number 26 Refrigeration System Evacuation 12 Duke Service Bulletin Number 35 Accessing Sealed Refrigeration Systems 13 SERVICE INFORMATION i a umasa asa stares go Petre PE qa do ala ao P aaa 14 MAINTENANCE Z kau a aqawan aaa dain da daj b da EE ege d e 14 Stainless Steel Care and Cleaning u ee ee eee 0000000000000 eee eee nenene eee 14 CV CATING PRO O O O L RE S VONN 14 Preserving K Restoring ii uu nu sunan ee da dada Ha Zi au ees 14 Heat EE 14 Compressor Ait Filter Cate icc resme E EE EE EEE 14 TROUBLESHOOTING GUIDE Lu aan srawaqanaqasasuswaquaypassqapkisqaassasQaysaqyaakaQukagsaq 16 e El e ER 18 Service Manual for KT Counter INTRODUCTION KT COUNTER SPECIFICATIONS MODEL VOLTAGE AMPERAGE WATTAGE PHASE KFC KT 208 15 4 3200 1 INSTALLATION Location The KT Counter is intended for indoor use only Be sure the chosen location has a floor strong enough to support the total weight o
5. on the front and rear of the unit Clean the air filters with mild soap and water once a month ee service Manual for KT Counter 1 Lift the louvered vent panel up and away from the front CAUTION Do not use a high pressure hose to rinse of the unit the filters The high pressure water will damage the filter mesh 5 Allow the filters to dry thoroughly before reinstalling them 2 Gently pull the filters out of their mountings 6 Install the filter and reattach the louvered vent 7 If replacement filters are required refer to the parts list for the correct part number Figure 20 Air Filter Cleaning 3 Wash the filters in a mild soap and warm water solution 4 Rinse with warm water 15 Service Manual for KT Counter TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSE REMEDY KT Counter does not operate No Power Make sure Main Power switch is in the ON position Check Main Circuit Breaker KT Counter has power but No Power Make sure Tortilla Griddle Power Switch is in Tortilla Griddle does not heat Bad Power Switch Open Tortilla Griddle Heat Element the ON position Check Tortilla Griddle Circuit Breaker in Load Center Replace Tortilla Griddle Power Switch Replace Tortilla Griddle Heat Element KT Counter unit has power but Dry Channel Unit will not heat No Power Bad Power Switch Display Control Panel Malfunction Relay Box failure Make sure Dry Channel Power Switch is in ON p
6. side with the temperature display is considered to be the front of the refrigerator unit The refrigerator s compressor is located behind the louvered vent to the left of the left front door Evaporator Fan Assembly The Evaporator Fan Assembly is accessed through the louvered panel on the inside of the RBC The assembly is equipped with two fans 1 Place the Main Power ON OFF switch in the OFF position 2 Perform proper Lockout Tagout procedures 3 Open the RBC doors and remove the shelf for easier access to the louvered panel 4 Remove the louvered on the inside wall of the RBC to gain access to the Evaporator Fan Assembly Service Manual for KT Counter 10 Screws Evaporator Fan Assembly Figure 12 Evaporator Fan assembly Remove the thumbscrews securing the Evaporator Fan Assembly to the Evaporator Assembly Carefully lift the Evaporator Fan Assembly out of the Evaporator Assembly Be careful not to pull to hard on the fan wiring Evaporator Fan Bracket Evaporator Fan Figure 13 Evaporator Fans Tag and disconnect the Evaporator Fan wires A separate bracket secures each fan remove the 2 nuts securing the faulty fan Reverse this procedure to install a new Evaporator Fan RBC Thermostat Figure 14 Location of the Refrigerator Thermostat The RBC Thermostat is located in the compressor compartment behind the louvered vent 1 m Bomo Place Main Power ON O
7. 16636 The smaller doors use a 17 inch gasket part number 216645 1 Pull gasket out of door panel groove 2 Press new gasket in groove 3 Ensure door seals properly To test for proper seal use a sheet of paper approximately the size of dollar bill Close the door on the piece of paper it should pull snugly 4 Adjust door as necessary RBC Door Adjustment Over time and with repeated use the RBC doors may begin to sag When this occurs door adjustment is required 1 Open the sagging door to its full open position 2 Check the hinges for tightness If they are loose snug them up but don t over tighten them 3 Place a flat headed screwdriver against the inside edge of the top hinge tap it with a small hammer using light taps until the door is lined up 4 Repeat for the bottom hinge if needed 5 Tighten all of the hinge screws LOAD CENTER Load Center Figure 17 Location of KT Counter Load Center The Load Center is located behind the cabinet door on the end of the unit nearest the Dry Channel Warmer 11 Service Manual for KT Counter Circuit Breaker Replacement Mm s r b a Circuit Breakers Figure 18 Location of Circuit Breakers Place the Main Power ON OFF switch in the OFF position Perform proper Lockout Tagout procedures Tag and disconnect the affected circuit breaker wires Pull th
8. BLACK WHITE BLACK BLACK WHITE WHITE GREY cxt 1 158 Hi cat 2 mm HD 5 6 CKT 3 30A CKT 4 20A 7 8 CKT 5 20A A cKT 7 204 CKT 6 20A Ia KT 8 15A DCH BA o CKT 9 20A CKT 10 ml CKT 11 15A oha CKT 12 15A 19 20 21 22 ED PANEL BOX A WALK UP SIDE RED RED T d Ee S T E Ge HOLDING BINS Figure 21 Wiring Diagram Side A 208v 15 44 32004 16 20 SINGLE 18 D MNN 8 vesi e SE IL GREEN cue E sss ste g DAR Service Manual for KT Counter FIELO JOINT GREEN U I m ET Wu VEL NOGI NOSNO Ai Ian GWH wm wn W GEL WHITE BLUE FIELD_JOINT WHITE BLUE E WE UD YSI 6 19 WL L WSL CJ VOZ C HEN DI u W Z DI wei 1 0 W Z WZ DO 8 X08 T3NYd XS d Figure 22 Wiring Diagram Side B 19 Service Manual for KT Counter Your Solutions Partner Duke Manufacturing Co 2305 N Broadway
9. FF switch in the OFF position Perform proper Lockout Tagout procedures Open the louvered vent Tag and disconnect RBC Thermostat wiring Disconnect the capillary tube be careful not to kink the tube Remove RBC Thermostat from mounting bracket Reverse these procedures to install a new RBC Thermostat Set the new thermostat according to Subway standards Restore power to the KT Counter monitor the RBC for proper operation Readjust the thermostat setting as needed RBC Refrigeration System Refrigeration Side Unit Louvered Panel Figure 15 RBC Refrigeration System 1 Place Main Power ON OFF switch in OFF position 2 Perform proper Lockout Tagout procedures Evacuate coolant following procedures in the RECHARGING REFRIGERATION SYSTEM section of this manual Remove center shelf for easier access Remove the side louvered panel Tag and disconnect wiring Remove Refrigeration Unit mounting hardware St ht Oy m ZS Remove the screws holding the evaporator assembly to the RBC cabinet 9 Reverse procedure to install new Refrigeration Unit RBC Door Gaskets Refrigerator Door Gasket Figure 16 Refrigerator Door Gasket Service Manual for KT Counter The RBC unit is a 4 door model with access from both sides of the KT Counter Two of doors one on each side are larger For the larger door use 19 inch gasket part number 2
10. Service Manual Your Solutions Partner KT COUNTER Please read this manual completely before attempting to install operate or service this equipment This document is prepared for trained Duke service technicians It is not to be used by anyone not properly qualified to perform these procedures This Service Manual is not all encompassing If you have not been trained on servicing this product be sure to read the manual completely before attempting servicing Be sure all necessary tools test equipment and skills are available Those procedures for which you do not have the proper skills and test equipment must be performed only by a qualified Duke trained service technician This manual is Copyright 2010 Duke Manufacturing Co All rights reserved Reproduction without written permission is prohibited Duke is a registered trademark of the Duke Manufacturing Co Duke Manufacturing Co 2305 N Broadway St Louis MO 63102 Phone 314 231 1130 Toll Free 1 800 735 3853 Fax 314 231 5074 www dukemfg com P N 229050A Service Manual for KT Counter IMPORTANT WARNING AND SAFETY INFORMATION THIS MANUAL HAS BEEN PREPARED FOR PERSONNEL QUALIFIED TO INSTALL ELECTRICAL EQUIPMENT WHO SHOULD PERFORM THE INITIAL FIELD STARTUP AND ADJUSTMENTS OF THE EQUIPMENT COVERED BY THIS MANUAL READ THIS MANUAL THOROUGHLY BEFORE OPERATING INSTALLING OR PERFORMING MAINTENANCE ON THE EQUIPMENT A WARNING Failure to fol
11. St Louis MO 63102 Phone 314 231 1130 Toll Free 1 800 735 3853 Fax 314 231 5074 www dukemfg com 20 P N 229050
12. comply can cause property damage injury or death A WARNING In the event of a power failure do not attempt to operate this appliance Failure to comply can cause property damage injury or death ee service Manual for KT Counter TABLE OF CONTENTS INTRODUCTION u see Ge esa aaa o ao ah aici ace Sate VR GAS Pod 4 KT COUNTER SPECIFICATIONS iu u a aaa TEETE ei 4 KENE DEEN RRE 4 LOCION uu ss RO O O O O O O O E LE 4 Electrical Connections secano e a a a a A kada do dade dado go dao 4 PARTS REMOVAL AND REPLACEMENT PROCEDURES een 5 ELECTRICAL LOCKOUT TAGOUT PROCEDURE eee 5 HOT FOOD TABLE AND DRY CHANNEL WARMERS a 5 Toggle SWIfe h S iiinneag a ahua SN gieren 5 Display Control PANEL sis sei ai ta ea EEA E 5 EE 6 Dry Channel Power ON OFF Toggle Swatch vat eeoa odao sake skoka tata ovna 6 Solid State Relay SSR ss scscdeasseescdegceevsvd xeucies sieeekaadvcasenacedesaee sad Dei a bona DAO VRAG goa 7 RRE 7 Channel Assembly esnean SSS uuu te ee 7 TOP COLD PAN ASSEMBIY u ua a ansa aaa ushata eased ines dame ode kaki n 8 EVaporalOF vsoti ssc sd O P O Eege 8 ThBermostati u ua EI EI VERE RE OE SEO EO ANN 8 Top Cold Pan Compressor Assembly nci nresnani a TE AD ten tk 9 REFRIGERATED BASE UNIT a a cents kebab ove eb E aa 9 Evaporator Fan AssemblY si sis sivine pih deni eege ib bk cadets conaevessuueielaneegesendaxt daseageussenveusentcs 9 RBC Thermostat ss usa kahata unata eege onada etek 10 RBC Refrigeration
13. ded Top Cold Pan Compressor Assembly Tri Channel Compressor Figure 10 Compressor Assembly The Top Pan Compressor Assembly is located behind the louvered vent next to the refrigerator It is on the side of the KT Counter that does NOT have the refrigerator temperature display 1 Place the Main Power ON OFF switch in the OFF position Perform proper Lockout Tagout procedures Remove the louvered vent Remove the air filter Remove side panel Tag and disconnect compressor wiring MA A B 6 R Disconnect coolant tubing from evaporator unit Refer to the RECHARGING REFRIGERATION SYSTEM section of the manual for proper evacuation procedures 8 Remove mounting bolts 9 Slide compressor unit out through the front of the unit 10 Install new compressor assembly 11 Reattach braze coolant lines 12 Reconnect compressor wiring 13 Reconnect wiring 14 Charge the cooling system Refer to the RECHARGING REFRIGERATION SYSTEM section of this manual for proper charging procedures 15 Attach air filter and all panels 16 Restore KT Counter to service and check for proper compressor operation Service Manual for KT Counter REFRIGERATED BASE UNIT Compressor Refrigerated Compartment Base Temperature Display Figure 11 Refrigerator Unit with Temperature Display The refrigerator unit is located below the Top Cold Pan Unit The refrigerator can be accessed from both sides of the KT Counter The
14. e circuit breaker out of its mounting slots Push the new circuit breaker into the slot ensure that it locks into position Refer to the tags and reconnect the wires Restore the KT Counter to service and check the circuit breaker for proper operation NOTICE Referto Troubleshooting section ifreplacement breaker does not solve problem 12 RECHARGING REFRIGERATION SYSTEM Tools Standard hand and refrigeration tools Refrigerant Type R 134A or R0404A Refer to the unit s specification tag for the correct refrigerant type NOTICE Alwayshave the serial number of the refrigeration unit whenever ordering refrigeration parts Duke Service Bulletin Number 26 Refrigeration System Evacuation NOTICE prior to refrigeration system service special care must be taken during the evacuation process to remove air moisture and other non condensable gasses from the system Duke Manufacturing recommends the following triple evacuation method Failure to follow this procedure may result in poor refrigeration system performance 1 Evacuate system to 1500 microns 2 Break vacuum to 2 psig with dry nitrogen Ifdry nitrogen is unavailable use same type of refrigerant as used in system 3 Evacuate system to 1500 microns 4 Break vacuum to 2 psig with dry nitrogen Ifdry nitrogen is unavailable use same type of refrigerant as used in system 5 Evacuate system to 500 microns The syste
15. f the unit fully assembled and loaded with food product Reinforce the floor if necessary to provide for maximum loading For the most efficient operation be sure to provide good air circulation Leveling The unit must be leveled during the installation process Refer to the KT Counter Operation and Installation Instructions Duke part number 229350 If additional leveling is required each module of the unit is equipped with adjustable feet Always use a level to adjust the KT Counter Use the leg adjustments to ensure that the unit is solid to the floor surface at all contact points Ensure that the unit does not rock when pressure is applied to the top corners Electrical Connection The KT Counter requires 208VAC 3 Phase 50 60 Hz Direct wiring KT Counter to the power supply must be performed by a certified electrician and must comply with local electrical codes WARNING REFER TO THE AMPERAGE DATA LIST IN THE SPECIFICATIONS OR THE SERIAL TAG DATA AND YOUR LOCAL CODE OR THE NATIONAL ELECTRICAL CODE TO BE SURE UNIT IS CONNECTED TO THE PROPER POWER SOURCE A PROTECTED CIRCUIT OF THE CORRECT VOLTAGE AND AMPERAGE MUST BE RUN FOR CONNECTION OF THE SUPPLY CORD OR PERMANENT CONNECTION TO THE UNIT THE POWER MUST BE TURNED OFF AND DISCONNECTED WHENEVER PERFORMING MAINTENANCE OR REPAIR FUNCTIONS Service Manual for KT Counter PARTS REMOVAL AND REPLACEMENT PROCEDURES ELECTRICAL LOCKOUT TAGOUT PROCEDURE
16. fter completing proper evacuation method recharge system using proper refrigerant according to information on the data plate Refrigerated Base Unit 8 oz of R 134a refrigerant Tri Channel Cold Pan Unit 16 oz of R404a refrigerant Continue crimping process hose just below temporary valve and again 2 below crimp With crimp tool in place remove temporary valve Braze shut end of process hose Allow to cool for about 5 minutes Remove crimp tool 10 Check brazed end for leaks Service Manual for KT Counter SERVICE INFORMATION MAINTENANCE Stainless Steel Care and Cleaning Cleaning Stainless steel contains 70 80 iron which will rust if not properly maintained It also contains 12 30 chromium which forms an invisible passive protective film that shields against corrosion If the film remains intact the stainless steel will remain intact However if the film is damaged the stainless steel can break down and rust To prevent stainless steel breakdown follow these steps CAUTION Never use any metal tools Scrapers files wire brushes or scouring pads except for stainless steel scouring pads will mar the surface CAUTION Never use steel wool which will leave behind particles that rust CAUTION Never use acid based or chloride containing cleaning solutions which will break down the protective film CAUTION Never rub in a circular motion CAUTION Never leave any food products or salt on the surface Ma
17. low all the instructions in this manual can cause property damage injury or death A WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death AWARNING Electrical connections should be performed only by a certified professional A WARNING Electrical and grounding connections must comply with the applicable portions of the National Electric Code and or all local electric codes Failure to comply with this procedure can cause property damage injury or death A WARNING Before connecting the unit to the electrical supply verify that the electrical and grounding connections comply with the applicable portions of the National Electric Code and or other local electrical codes Failure to comply with this procedure can cause property damage injury or death A WARNING Before connecting the unit to the electrical supply verify that the electrical connection agrees with the specifications on the data plate Failure to comply with this procedure can cause property damage injury or death A WARNING UL73 grounding instructions This appliance must be connected to a grounded metal permanent wiring system Or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the appliance Failure to comply with this procedure can cause property damage
18. m is now ready to receive refrigerant charge according to information on data plate AWARNING NEVER USE OXYGEN OR ACETYLENE IN PLACE OF REFREGERANT AND DRY NITROGEN FOR LEAK TESTING A VIOLENT EXPLOSION MAY RESULT CAUSING PERSONAL INJURY OR DEATH ALWAYS USE A PRESSURE REGULATOR WHEN USING NITROGEN TO PRESSURE TEST FAILURE TO DO SO WILL RESULT IN EXTREMELY HIGH PRESSURE WHICH COLD EXCEED THE BURST PRESSURE OF THE COMPRESSOR OR OTHER SYSTEM COMPONENTS AND RESULT IN PERSONAL INJURY OR DEATH Duke Service Bulletin Number 35 Accessing Sealed Refrigeration Systems To analyze the performance of a refrigeration system record temperature readings Convert temperature into pressure using a standard pressure temperature chart When it is necessary to service a factory sealed refrigeration system and return it to its properly sealed condition strictly adhere to the following approved procedure NOTE Ensure that there is enough process hose approximately 12 available to complete the repair If not install a new process hose before repair sequence 1 Install a temporary access valve on the high and low side of process hoses as close to factory crimps as possible Use temporary valves to perform repair Note Duke Manufacturing will not reimburse the cost of permanently installed valves After completing repair evacuate system using the triple evacuation method o me ND Service Manual for KT Counter A
19. nd disconnect the wires from the foil wrap on the Channel Assembly to the Control Board 5 Using an ohmmeter test the resistance across the entire heating element It should read approximately 2480 Also test the RTD circuit its normal reading is approximately 1 000Q Replace the channel assembly if either the heater circuit or RTD circuit are reading out of tolerance 6 Reverse this procedure to install the new Dry Channel Assembly Transformer 7 Return the Dry Channel unit to service and check for proper operation Figure 6 240 208 Step Down Transformer 1 Tag and disconnect the wires from the Transformer 2 Remove fournuts attaching the transformer and remove the Transformer 3 Reverse procedure to install a new Transformer Service Manual for KT Counter TOP COLD PAN ASSEMBLY Top Cold Pan Figure 8 Cold Pan Unit The KT Counter is equipped with two Cold Pans Both Cold Pans are mounted above the refrigerator unit and angled toward the operator on each side Refer to Duke Manufacturing Service Bulletin Number 26 and the Recharging Refrigeration System section of this manual before completing Evaporator replacement procedures Evaporator The evaporator coils embedded in the body of each Cold Pan are not serviceable Replace the entire Top Cold Pan Assembly if an evaporator leak or failure occurs 1 Place the Main Power ON OFF switch in the OFF position 2 Perform proper Lockout Tagout procedures
20. ny foods are acidic Salt contains chloride For routine cleaning use warm water mild soap or detergent and a sponge or soft cloth For heavy duty cleaning use warm water a degreaser and a plastic stainless steel or Scotch Brite pad Always rinse thoroughly Always rub gently in the direction of the steel grain Preserving amp Restoring Special stainless steel polishing cleaners can preserve and restore the protective film Preserve the life of stainless steel with a regular application of a high quality stainless steel polishing cleaner as a final step to daily cleaning If signs of breakdown appear restore the stainless steel surface First thoroughly clean rinse and dry the surface Then on a daily basis apply a high quality stainless steel polish according to manufacturer s instructions 14 Heat Tint Darkened areas called heat tint may appear on stainless steel exposed to excessive heat which causes the protective film to thicken Itis unsightly but is nota sign of permanent damage To remove heat tint follow the routine cleaning procedure Stubborn heat tint will require heavy duty cleaning To reduce heat tint limit the exposure of equipment to excessive heat Compressor Air Filter Care YY Mi DOANE BRA ROE Air Filters Louvered Panel Figure 19 Location of Compressor Air Filters The Compressor Air Filters are located behind the large louvered vent mounted
21. osition Check Dry Channel Display Control Panel setting should be 275 F Check Dry Channel Circuit Breakers Replace Power Switch Replace the Display Control Panel Replace the Relay Box Dry Channel unit is working but one channel does not heat Open in Heat Element circuit Replace channel assembly KT Counter unit has power but No Power Make sure Taco Tower Power Switch is in ON Taco Tower doesn t heat or light position Check Taco Tower Circuit Breaker Taco Tower lights come on but it Failed Infrared Heater Replace Infrared Heater doesn t heat KT Counter unit has power but No Power Make sure Tri Channel Unit Power Switch is in Tri Channel unit doesn t get cold ON position Check Tri Channel Unit Circuit Breaker Check Thermostat setting 16 TROUBLESHOOTING GUIDE CONTINUED Service Manual for KT Counter SYMPTOM POSSIBLE CAUSE REMEDY Cold Pan Unit doesn t get cold Coolant Leak Defective Thermostat Dirty Compressor Air Filter Failed Condenser Cooling Fan Condenser Motor Failure Repair Leak referring to Duke Service Bulletin Number 26 Replace Cold Pan Replace Compressor Assembly Replace Cold Pan Thermostat Clean or replace Air Filter Replace Condenser Cooling Fan Replace Condenser Assembly KT Counter has power but Refrigerator does not get cold No Power Thermostat Setting Defective Thermostat Dirty Compresso
22. r Air Filter Failed Condenser Cooling Fan Coolant Leak Evaporator Fan Failure Door Gaskets Leaking Excessively Check Refrigerator Unit Circuit Breaker Check Thermostat Setting Replace Thermostat Clean or replace Air Filter Replace Condenser Cooling Fan Repair Leak referring to Duke Service Bulletin Number 26 Replace Compressor unit if needed Replace Evaporator unit if needed Replace Evaporator Fan Assembly Replace Door Gaskets Service Manual for KT Counter SCHEMATICS HOLDING CABINET DUKE HOCS 208v 10 14 mwa re o V EE 5 15 GECI RED s FIELD_JOINT RED FIELD JOINT BLACK 208 1734 xow o z z Sls 16 30 SINGLE 6 6 6 6 SUR di 3 zla EE SIS SIS d d i d i H ice a w l Ee HUN GREY GREY HUN CREY STAGER x 1201 684 R D 3 15 en o o o D Sib 4 l i BLACK l 208 1584 33004 1 8 20 DUPLEX BLACK WHITE BLACK WHITE a RE r BLACK Ee
23. se procedure to assemble and install Relay Box NOTICE The following component removal is based on the cover having been already removed Dry Channel Power ON OFF Toggle Switch 1 Tag and disconnect the Relay Box ON OFF Switch wires Slide the Relay Box ON OFF Switch out through front of switch mount Reverse procedure to install a new Main Power ON OFF Switch Note Location of Serial Data Plate Serial Number data plates 11 2007 and later Figure 4 Exploded View of Relay Box Internal Components Service Manual for KT Counter Solid State Relay SSR Channel Assembly The Heat Elements Temperature Probes and RTDs are embedded in a foil wrap that is attached to the bottom of each Channel Assembly These parts are not serviced in the field The entire Channel Assembly must be replaced in the event of a failure of any of these parts 1 Follow proper LOCKOUT TAGOUT procedures 2 Remove six screws three on each side attaching the channel top frame to the tub 3 Carefully lift the Channel Assembly out taking care not to damage wire connections Channel Assembly Solid State Relay SSR Figure 5 Solid State Relays SSR 1 Tag and disconnect wires from the SSR to be replaced 2 Remove the two screws attaching the SSR and remove the SSR 3 Reverse procedure to install a new SSR Transformer Figure 7 Dry Channel Tub Assembly 4 Label a
24. wires to the faulty switch remove the wires and discard the switch 6 Attach the wires to the replacement switch 7 Install the new switch and reattach the switch plate 8 Place the unit back in service and check it for proper operation Display Control Panel The KT Counter is equipped with two dry channel units installed in the Hot Food Table Each dry channel unit has its own Display Control Panel O DIS F es HEAT ON PS Wm A izav Function Control Select Button Buttons Figure 2 Dry Channel Display amp Control Panel 1 Follow proper LOCKOUT TAGOUT procedures 2 Remove the four screws securing the Display Control Panel and carefully pull Display Control Panel away from mounting surface 3 Ifthe Display Control Panel isto be completely removed label and disconnect wires 4 Remove Display Control Panel 5 Reverse procedure to install Display Control Panel Relay Box Each Dry Channel unit is equipped with its own Relay Box The Relay Box is located under each unit Each Relay Box has an ON OFF switch Service Manual for KT Counter as Figure 3 Relay Box 1 Follow proper LOCKOUT TAGOUT procedures 2 Remove the four screws securing the Relay Box to the bottom of the Dry Channel Unit If complete Relay Box is to be replaced label and disconnect wires Remove the Relay Box If components in the Relay Box are to be removed remove the Relay Box cover Rever
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