Repair Procedure
Fusible Link
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The machine is protected from overheating by a length of special wire. In the rare occurrence that the safety features of the machine fail and the roasting chamber overheats, the Fusible Link melts.
Begin by following these procedures:
Cooling tray
Front Cover
Bearing Plate and Drum
Remove Fan
Remove Rear Cover
Remove Top Cover
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Before beginning this procedure, check to see that your roaster has the jumper-resistor connected to terminals T3 and T4 as shown here. If it does not, you must follow THIS PROCEDURE.
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Cut the tie wrap(s) holding the wire bundle above the Main Circuit Board together. Discard the clippings (Do not leave them in the machine).
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NOTE: Over time there has been some variation on the colors of some of the wires. The wires you will be dealing with may be red or may be white. So long as you chose the correct wires as identified by their connection points the color of the wires does not matter.
Examine the wires connected to terminals T5 and T6. One wire connects to the Heating Element. The other is part of the Fusible Link. Identify the one that is the part of the Fusible Link, and using a needle nose pliers, remove that wire. Be aware that it may be connected to EITHER Terminal T5 or at T6. Note that your board may look somewhat different from that shown here, but terminal numbering is the same for all KN-8828X roasters.
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Follow the directions to Remove the Motor. It is NOT necessary to completely remove the motor. Just the 4 screws holding the motor's mounting bracket to the machine. No wires need to be removed. Looking at the rear of the machine, move the motor off to the left to revel the fusible link. Do not allow the motor to hang by its wires. If you cannot safely support the motor either get assistance or remove it completely.
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Remove the other wire lead from the Fusible Link that connects to the Heating Element. The position of the wires may be reversed from the positions shown here. That is, the Fusible Link's wire you are removing in this step may be attached to the lower Heating Element's connection point.
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Remove the screw holding the old Fusible Link and remove it along with its bracket. Feed the longer white lead up through the hole in the metal base plate and remove the old Fusible Link.
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INSTALL THE NEW FUSIBLE LINK
Attach the bracket that was included with the repair kit to the new Fusible Link. Do not reuse the old bracket!
IMPORTANT: note that the bracket attaches to the center of the fusible link on an area marked similar to that shown here. This is the center, firm portion of the Fusible Link. Not attaching the bracket in the correct location could result in damage to the Fusible Link and/or a fire hazard.
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Loosely attach the new Fusible Link to the roaster using the same hole. Use the new screw included with the kit. Be sure that the center portion of the fusible link located under the bracket of the fusible link sits flat against the back wall of the roasting chamber and that no wires are trapped under the new link. Be sure to locate the fusible link and its wiring are located so that they cannot contact the heating element.
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Move the top end of the new Fusible link so that it is clear of the mounting hole for the Main Motor bracket. The wires in the link can be bent, but take care not to bend them close to the link itself which can be felt through the insulating layer as a stiff, tubular shape in the area of the bracket. When the link is clear of the hole as shown here, tighten the screw. Once again, make sure that the link is firmly up against the metal plate to which it is mounted.
WARNING!: The fusible link is part of the safety system designed into the Hottop coffee roasters. Its operation depends on sensing the heat of the roaster. It must be in firm contact with the metal of the roasting chamber as descried above. Failure to assure that this is done correctly can create a fire hazard!
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The Fusible Link has two wire leads. The short lead with the woven insulating cover attaches to the heating element. One wire coming from teh Main Board is already attached to one connector of the heating element. The short Fusible Link wire with teh woven sleeve insulation attaches to the other heating element connector. It does not matter which of the two heating element terminals you use for the Fusible link. The arrow here indicates that in this particular installation the Fusible Link is being attached to the upper Heating Element terminal.
IMPORTANT: Be sure to check that both spade connections on the heating element are tight. If loose, remove and use a small pair of pliers to carefully squeeze the female spade clips closed a bit and check for proper fit again. Use caution when pushing on the heating element's attachment points.
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CONNECT FUSIBLE LINK TO THE MAIN BOARD - The two wires indicated here are:
1) The lead from the Fusible Link
This is the longer lead with the black insulation at the terminal end from the new Fusible Link. Feed it through one of the holes in the metal dividing plate down to the Main Board.
2) The lead from the Heating Element.
These two wires connect to terminals T5 and T6. It does not matter which lead is on which terminal, so long as these two leads connect, one each, to these two terminals.
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To complete the procedure:
Replace the Motor
Replace the tie wrap(s) on the wires leading to the main board
Replace Top Cover
Replace Rear Cover
Replace the Main Fan
Replace the Drum and the Bearing Plate
Replace Front Cover |
