Merco Savory POP-2/4 User's Manual
Contents
1. Merco Savory INSTALLATION amp PARTS AND SERVICE MANUAL POP 2 4 POP UP TOASTER The POP 2 4 Pop Up Toaster is designed to allow the operator to toast a wide vaariety of bread products The wide mouth opening 1 will accommodate varioues thicknesses of bread from thin sliced to Texas toast Each of the two toasting slots can hold one or two slices of bread and the self centering toast guides assure each slice regardless of thick ness will be perfectly toasted time and time again All controls are located on the front toaster panel The POP 2 4 is engineered for efficient de pendable service throughout the years Like any piece of fine equipment with moving parts and broad temperature ranges physical wear can take its toll When this happens the infor mation found in this manual will prove helpful Merco Savory Inc 1111 North Hadley Road Fort Wayne IN 46801 Phone 800 547 2513 Fax 260 436 0735 www mercosavory com TABLE OF CONTENTS OPERATING INS TUG TON Gessner a Acta 2 CLEANI GINSTRUC TIO S ze ccc z Z 2 INSTALEANIONEG ono ao R no ai 3 SPECIFICATION Se oai Gai ai a 3 WARRANTY gt gt va ao Gada ee 3 SEQUENCE OF OPERATION OSA O EZ 4 WIRING DIAGRAMS SSR i A Gi 4 PARTS REMOVAL INSTALLATION amp ADJUSTMENTS 5 8 OPERATING INSTRUCTIONS Due to the commercial stainless steel construction you may notice that a cold toaster requires more toasting2. OUTER HEATER CARD ASSEMBLY Remove case cover Section A Unhook the two toast level springs from the chassis top Straighten the 9 twist tabs on the chassis top OONOOARWD Remove upper chassis top Position wires from Release Button behind P C Board Release Button A 26162 208 220 240V 26239 Sensing Prabe Terminals 3 amp 4 Figure 3 Turn shaft full counter clockwise ee Knob Cap Lighter Darker Figure 4 With pliers straighten corresponding twist tabs on underside of toaster On underside of toaster remove corresponding sheet metal screw securing the end panel to the base Slide rear exterior panel down the power cord away from the toaster When replacing left side heater card remove strain relief bracket securing power cord to the inside panel With retaining ring pliers remove the upper retaining rings from both guide shafts 10 Remove upper and lower terminal connections from the outer heater card NOTE When replacing left side heater remove tap wire 11 Straighten twist tab securing the heater card assembly to teh inner front end panel 12 On the inner rear end panel straighten the center and corresponding twist tabs 13 Carefully pushing outward on both end panels lift the heater card assembly upward 14 WEhen installing new heater card aassembly make sure all internal components are positioned correctly at both ends of the toaster Figure 8 WARNING BOTTOM VI
3. EW OF TOASTER FOR MODELS MANUFACTURED BEFORE 9 1 90 Sheet metal screws securing end panel WHEN ATTACHING WIRE CONNECTIONS lt MAKE SURE CARGLAS SLEEVING IS FULLY INSERTED THROUGH OPENINGS AND COMPLETELY COVER TERMINAL ENDS FAILURE TO DO SO WILL CAUSE ELECTRICAL SHORTING 9 Twist Tabs G Center Heater Card Assembly Remove case cover Section A Remove 4 machine metal screws securing upper chassis Straghten twist tabs on upper chassis Disconnect both return springs at front of unit Remove both snap rings on upper chassis Slip off 2 heater jumper wires from chassis tabs Lift off upper chassis Lay unit on side On underside of unit straighten center row of twist tabs Centering 9 Remove 2 screws securing end panel to lower chassis Spring RH igure 7 26034 10 Note If thermal barriers are present on unit remove the 4 screws securing barrier to end panel Do not remove not shown barriers Figure 5 11 Straighten 3 twist tabs on end panel and the 1 tab on center front panel Pull off end panel 12 Disconnect wiring connections to center heater card assembly 13 Slide out center card assembly 14 When replacing individual heater cards on center heater card assembly be sure to note correct positioning of ceramic spacers These spacers MUST be in correct position when new cards are attached 15 NOTE Left side heater card has tap wire When installing this card be sure tap wire faces f
4. IRING DIAGRAM 120V Revised2 4 91 After Serial Number PU 4999 R H HEATER 26167 L H HEATER RH HEATER L H HEATER 26028 POWER SWITCH 3 5 26048 CONTROL CONTROL POWER BOARD BOARD SWITCH 26238 26238 26048 RESET SWITCH 51207 RESET R SWITCH v 51207 a CORDSET NEMA 5 15P WIRES WELDED ON R H HEATERS 26158 POP 2 4 WIRING DIAGRAM 208 220 240V After Serial Number PU 4999 L H HEATER R H L H R H HEATER ASSEMBLY HEATER HEATER ASSEMBLY 26183 26029 26241 26186 POWER SWITCH CONTROL 26048 CONTROL BOARD BOARD POWER SWITCH 26239 26239 26048 8 RESET SWITCH 51207 RESET SWITCH o 51207 CORDSET NEMA 6 15P 26159 REMOVAL INSTALLATION AND ADJUSTMENTS CAUTION UNPLUG UNIT AND ALLOW TO COOL BEFORE ATTEMPTING ANY SERVICE PROCEDURES IN THIS MANUAL A CASE COVER CONTROL PANEL 1 Carefully place toaster upside down on a non abrasive surface 2 Remove crumb tray 3 Pry our rubber foot plugs adn use 1 3 nut driver to remove legs 4 Push panel sides outward to gain clearance and slide out floor panel 5 Push panel sides outward and lift out toaster chassis 6 Unscrew both toast level handles and remove 7 Remove one screw securing control panel to upper chassis 8 Remove 2 screws securing control panel to lower chassis 9 Gently pull control panel forward to gain access tothe inner workings End Plate n
5. d may damage the unit will void the warranty and may cause injury ELECTRICAL SPECIFICATIONS VOLTAGES AMPERAGE MAX POWER FREQUENCY PHASE CORD PLUG VOLTS AC AMPS KW HZ SUPPLIED SUPPLIED 50 60 1 3 20 96 24 _ 5060 1 3 NEMA 6 15 NOTE Non U S A models supplied without plug The circuit on which the receptacle is installed must be of adequate wiring size and sufficient capacity to meet the requirements indicated on the unit data plate and in conformance with the National Electrical Code and local electrical installation codes Failure to meet these requirenments will void the warranty SPECIFICATIONS Standard Models 120V VOLTAGE AMPS NETWT SHIP WE SHIP VOL 208V 240V NEMA 5 15P NEMA 6 15P 3 foot cord and plug configuration PRODUCT 120V 208V 240V KW ibs kg lbsfkg cu ft cu m 726000 148 18 18 89 18 6 10 002 zeo 86 21 13 59 136 tooo 726001 wa 25 13 59 13 6 10 002 Measurements are approximate MECHANICAL DIMENSIONS inches cm 717 8 gt 14 35 6 7 625 18 7 PERECA 12 25 31 1 ere WARRANTY The POP 2 4 toaster is guaranteed to be free of defects in material and workmanship for a period of one 1 year from date of purchase or 18 months from date of shipment from the factory whichever comes first provided that the equip ment is utilized to the manufacturer s r
6. ecommendations and instructions The POP 2 4 is warranted on an exchange basis only Please contact our Service Department at 1 800 701 2992 for information A warranty registration card is provided with each toaster Complete all equested information on this card and return to Merco Savory Inc immediately to insure proper warranty registration Damage resulting from accident alterations misuse abuse improper installation or failure to follow use and care instructions will void the warranty The warranty is applicable in the Continental U S A and Hawaii only 3 SEQUENCE OF OPERATIONS On the POP2 4 toaster the sequence of operations is separate but identical for both left and right toasting slots Power is permanently supplied to the power switch Depressing the toast arm closes the power switch which supplies voltage to the control board The control board energizes an electro magnet which holds the toast arm in a down position The control board also supplies power to the heating elements Adjusting the Light Dark knob will change the amount of time that the elements are energized and the toast arm is held in the down position At the end of the cooking cycle the electro magnet and the heating elements and de energized along with the toast arm being returned to the up position Depressing the manual release button during the toast cycle de energizes power to the control board and returns the toaster to the starting position POP 2 4 W
7. lever s 3 When toasting cycle is completed finished product will automatically be released Remove immediately to prevent drying out CAUTION Operation of this unit without product in the toasting slos will cause excess heat to be absorbed by the electrical components rather than the intended bread product This will significantly reduce the operational life of these components CLEANING INSTRUCTIONS CAUTION UNPLUG TOATER AND ALLOW TO COOL BEFORE CLEANING The POP 2 4 is designed for easy cleaning The lustrious outer surfaces need nothing more than a daily wiping with a soft cloth The crumb tray may be removed and wiped with a soft damp cloth to remove any crumb build up DO NOT OPERATE THE UNIT WITHOUT A CRUMB TRAY Do not use abrasive cleaners on any part of the toaster This will cause damage to the finish of the unit 2 INSTALLATION Install the POP 2 4 in the most convenient location for ease of cleaning maintenance and general operation Avoid installing in locations with drafts close proximity to grease or vapor producing appliances or other high ambient heat equipment Allow approximately 1 clearance on sides and back of unit for proper air circulation Allow sufficient overhead clearance for proper operation of this unit WARNING This toaster must be plugged into the proper voltage which is specified on the data plate located on the back panel of the toaster Use of any other voltage or altering of the plug or cor
8. ol shown Heat Control Knob Assembly 25116 26193 Release Button 4 p R Bezel Nut 51207 p 51208 Toast Handle Assy i 26192 a pad gt Decal 26032 Case Cover 26176 ee Foot Plug nol shown Floor Panel not shov 51038 26114 Figure 1 B RELEASE BUTTON 1 Remove case cover adn control panel Section A 2 Remove bezel nut and star washer from release button 3 Push release button through panel and remove push terminals 3 and 4 from p c board 4 When re attaching new push terminals to p c board polarity is not a factor Refer to wiring diagram 5 IMPORTANT When installing new release button make sure both wires are positioned behind p c board P C Board Reflector Figure 2 C P C BOARD 1 Remove case cover and control panel Section A 2 Remove knob from front of control panel NOTE Thecontrol knob on the front panel consists of two parts the knob and the knob cap The cap must be snapped off before removing the knob Use a span ner wrench to loosen the knob and pull off the shaft 3 Remove wire connections from the p c board 4 Remove the 4 mounting nuts and remove the p c board 5 When installing the new p c board make sure the sensing probe is inserted through the opening in the p c board reflector before securing front panel to th chassis Figure 3 6 To replace the knob on the front panel turn the adjustment shaft fully counterclockwise Slip on th knob making su
9. rethe white indicator mark on the knob is alligned with the lowest setting mark Lighter on the control panel Hold the knob securely inposition and tighten with a spanner wrench Snap on the knob cap aligning the indicator marks on the knob and cap Figure 4 POWER SWITCH 1 Remove the case cover and control panel Section A 2 Remove wire connections from the p c board noting the proper orientation and remove the front control panel 3 Remove the black bushing from the toast lever mechanism IMPORTANT Mark the positioning of the bushing before removing 4 Remove the 2 mounting screws and nuts from the switch 5 Remove wire connections from the switch noting proper orientation Refer to the wiring diagram 6 For units with slots in the mounting brackets make sure the switch is fully forward in both slots E TOAST LEVER SPRING 1 Remove case cover Section A 2 Remove wire connections from power switch 3 Remove the groundingnut from the floor of the toaster 4 Open cable holding clamps with pliers 5 Remove the strain relief clamp securing the power cord 6 Pull the power cord out through the busing on the back panel F POWER CORD 1 Remove case cover Section A 2 Unhook the spring from both ends 3 Insert the new spring hooking the bottom end first Bring the top end of the spring through the small hole in the chassis cover and hook into th elarger hole 4 Check for proper jumper wire positioning G
10. ront of unit CONOR WND Centering Spring LH 26033 not shown 16 When replacing heater card assembly be sure all spacer eyelets Toast at ends of toast guides are in proper position Snap Ses i eturn Rings Springs FRONT OF TOASTER Figure 7 Figure 8 Proper eyelet spacer positioning on toast support guides ON MODELS WITH UNEQUAL SPACING BETWEEN Eyelet spacer VERTICAL RODS 26040 N eq sf Ceramic spacer 26051 Centering springs LH 26033 ON MODELS WITH EQUAL RH 26034 SPACING BETWEEN VERTICAL RODS Eyelet spacer 26040 Latch Plate Assy RH 26175 Screw i 41118 mi Retum sites Fe 51072 si Toast Support Rod 26121 Slide Bushing 26037 M Power Cord Assy z it Ra 120V 26158 m 7 la PDG i 494 Aj 208 220 240V 26159 NN eee Snap Bushings DLPh Figure 5 Heater reflector assy RH Snap ring 120V 26167 not shown 20B 220 240V 26186 z 14758 Center heater card RH w o wire 120V 26029 20B 220 240V F 26242 Ceramic spacer high toward inside 25050 Ve rtical toast g r ide 26027 Center heater card LH WIWI E 120W 256028 208 220 240V 26241 Heater reflector assy LH 120W 26164 208 220 240V r 26163 Ceramic spacer low toward outside panel 25050 Figure 6
11. time than a warmed up toaster Our specially designed electronic controls will automatically adjust to these conditions altering the toast cycle for either frequent or infrequent use The more the unit is used and the stainless steel warms up the faster it will toast until the miminum cycle rate is reached Once you find the optimum setting for your toasting requirements there is no need to continually adjust the setting NOTE THIS TOASTER IS NOT DESIGNED FOR BAGELS If your toast production varies white bread to rye to sourdough it may be necessary to make adjustments for the various products using the heat setting 0 10 We suggest a few test cycles with various types of products to determine your desired settings A midpoint number is recommended for your initial setting If you desire darker toast rotate the knob to a higher number or rotate to a lower number for lighter toast Some experimentation may be required to obtain specific results for individual products Dryness of bread voltage differences and sugar content all will have an effect on toast color Whole grain rye and other breads with lower sugar content will require a higher setting to produce medium toast 1 Place bread product into the slots NOTE One or two slices of the same thickness may be placed in each individual toasting slot toasting two different products at the same time be sure each slot is loaded with a similar thickness product 2 Depress Toast
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