Wells Waffle Iron BWB 1S User Manual

211  
WELLS MANUFACTURING COMPANY  
2 ERIK CIRCLE, P. O. Box 280  
Verdi, NV 89439  
Customer Service (775) 345-0444 Ext.502  
fax: (775) 345-0569  
SERVICE  
INSTRUCTIONS  
for  
BELGIAN  
WAFFLE  
BAKERS  
Model  
BWB-1S  
IMPORTANT: WELLS MFG. PROPRIETARY INFORMATION  
TECHNICAL CONTENT OF THIS MANUAL IS DESIGNED FOR  
USE BY QUALIFIED PROFESSIONAL TECHNICIANS ONLY  
Part No. 502972 Rev. A  
S211 111000 cps  
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TABLE OF CONTENTS  
General Safety Procedures  
Inside Cover  
Specifications  
1
2
3
Features and Operating Controls  
Servicing Precautions for This Equipment  
Troubleshooting  
4
Servicing Instructions  
Wiring Diagrams  
Parts Breakdown  
6
11  
12  
GENERAL SPECIFICATIONS  
DIMENSIONS  
Wide  
10-1/8”  
Deep  
14”  
High  
10-9/16”  
ELECTRICAL  
Voltage  
Amperage  
120 VAC 1Ø  
7.5 Amp  
Wattage  
Cord  
900 W  
NEMA 5-15P  
1
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FEATURES AND OPERATING CONTROLS  
17  
BACK VIEW  
48  
19  
9
43  
3
2
4
5
1
.1  
6
20  
40  
39  
73  
42  
16  
10  
28  
18  
47  
27  
75  
66  
48  
8
41  
BOTTOM GRID  
RIGHT SIDE VIEW  
INTERIOR VIEW  
back panel removed  
wiring cover removed  
shown in “open” position  
8.  
9.  
POWER CORD  
DATA PLATE  
115VAC NEMA 5-15P  
Specifies power requirements  
Initiates timer  
10.  
16.  
17.  
18.  
19.  
20.  
27.  
28.  
39.  
40.  
41.  
42.  
43.  
47.  
48.  
66.  
MICRO SWITCH  
TEMPERATURE PROBE  
HANDLEASSY  
SUPPORT BRACKET  
HOLE PLUG  
Thermistor temperature sensor  
Used to raise / lower / rotate grids  
Supports front of grids  
Allows access to timer adjustment  
Protect wiring in grids  
WIRING COVER  
TEMP. CONTROLLER  
INDICATOR LIGHT  
BEARINGASSY  
PIVOT ASSY  
In concert with thermistor, controls temperature of grids  
Lit during timed cook cycle  
Supports back of grids; allows grids to rotate  
Holds grids in alignment; allows grids to rotate  
Provide necessary non-slip support for waffle baker  
Cooking element; holds temperature probe  
Cooking element  
RUBBER FEET  
BOTTOM GRID  
TOP GRID  
BUZZER  
Sounds momentarily at end of cook cycle  
Audio alarm - warns operator of end of cook cycle  
Energizes the Waffle Baker  
TIMER  
POWER SWITCH  
(73.) (HI-LIMIT THERMOSTAT)  
75. DRIP TRAY  
Eliminated on later models. See page 11.  
Catches excess waffle batter for easier clean-up  
2
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PRECAUTIONS FOR SERVICING THIS EQUIPMENT  
Disconnect electrical power to equipment prior to performing cleaning or other service.  
In order to avoid electrical shock, injury and/or equipment damage, use appropriate  
precautions whenever electrical power must be restored for adjusting, calibrating or  
taking voltage measurements.  
Ensure that input power matches the nameplate data for voltage and phase.  
Input power circuit must meet or exceed the nameplate power requirements.  
Equipment is equipped with the proper electrical plug for the specific power  
requirements of the unit. DO NOT alter the power cord or plug. Never cut off a ground  
prong, or twist a prong, to allow the plug to fit an existing receptacle.  
CAUTION: This Wells Waffle Baker is equipped with a three-  
prong electrical plug. The three-prong plug is part of a system  
that will protect you in the event of an electrical wiring failure.  
Be sure the three-prong plug is plugged into a matching and  
properly grounded three-prong receptacle. DO NOT cut or  
break off the ground prong of this plug.  
OPERATING AN APPLIANCE WITHOUT PROPER GROUNDING  
CAN RESULT IN SERIOUS PERSONAL INJURY  
GROUND  
PRONG  
CAUTION: Test electrical receptacle for proper polarity. For the safety of personnel,  
it is important that electrical ground and electrical neutral are maintained as designed  
by the factory.  
CAUTION: DO NOT plug in or energize this appliance until Installation  
Instructions are read and followed. Injury to the operator and damage to the Waffle  
Baker may occur if these instructions are not followed.  
CAUTION: Never submerge electrical equipment in water.  
Avoid contaminating electrical components with water when cleaning cooking surfaces  
or cabinet.  
IMPORTANT: Never use a wire brush or metal scraper on aluminum components. Use a soft  
bristle, fiber brush to clean grids.  
Data sheets and text in this manual are representative of current production models as of  
November, 2000. Specifications, Model Numbers, Product Numbers and data are subject to  
change at any time without notice.  
Whenever servicing is required to correct electrical or temperature complaints, always refer service  
to a Wells Factory Authorized Service Agency.  
Refer to Wells Form #37000 for a complete listing of factory authorized service agency locations.  
3
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TROUBLE SHOOTING  
CAUTION: ELECTRIC SHOCK HAZARD  
Live electrical circuits are exposed  
during troubleshooting procedures  
CAUTION: BURN HAZARD  
Equipment surfaces will be hot  
during troubleshooting procedures  
B. TEMPERATURE CHECKS  
1.  
2.  
Desired baking temperature is 390ºF ±5ºF (200ºC ±3ºC).  
Turn the power switch ON and allow the Waffle Baker to heat for  
a minimum of 30 minutes. Insert a pyrometer of known accuracy  
betwen the grids and allow the readings to stabilize.  
390ºF  
CALIBRATION  
POINT  
3.  
Temperature may be adjusted by removing the back panel,  
and turning the dial on the temp controller:  
CW to decrease temperature; CCW to increase temperature.  
NOTE: Manufacturer’s calibration point (390ºF) is indicated by a black dot on the face of the dial.  
A. ELECTRICAL TEST POINTS  
TP1  
TP3  
TP2  
TP4  
ELEMENT / GRID  
bottom shown - top similar  
TEMPERATURE CONTROLLER  
test points are terminals  
TIMER MODULE  
test points are terminals  
B. AMPERAGE AND RESISTANCE CHECKS  
1.  
Amperage may be checked with an inductive amperage tester (Amprobe™ or similar) by encircling  
wire #4 at temperature controller terminal 2. Total amperage is 7.5 Amps with the waffle baker in  
the pre-heat mode.  
2.  
The heating element is integral with the Grid casting.  
Disconnect wire #7 to #8 from temperature controller to check resistance of both grids at once.  
Resistance from # 7 to #8 is 16W (cold) ± 1W. A reading of 32.0W indicates one defective element  
or a broken element jumper wire.  
Data for one element: 450 Watts, 3.8 Amps  
Resistance of one element TP1 to TP2, (wires disconnected) is 32.0W (cold) ± 1W.  
4
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D. VOLTAGE CHECKS  
NOTE: Resistance of the temperature probe is typically 5 megohm at room temperature, with  
resistance decreasing as temperature rises. A shorted temperature probe will cause a runaway  
condition, and an open probe will cause a continuous OFF condition.  
1.  
2.  
Voltage between temperature controller terminals 2 & 3 will be 120V any time the power switch  
(item 66) is turned ON. Absence of 120V indicates power switch OFF or defective, or a wiring or  
connector problem.  
Voltage between TP1 and TP2 will be 120V when the unit is calling for heat. Absence of 120V,  
when heating is required, indicates:  
a.) Power switch defective or OFF; or,  
b.) Temperature controller defective or open temperature probe; or,  
c.) Wiring or connector problem  
3.  
4.  
Voltage between TP1 and TP2 will be 120V when the unit is calling for heat. Failure to heat  
when 120V is present indicates that the element being tested is defective.  
Voltage between temperature controller terminals 1 & 3 will be 120V when the thermostat is  
calling for heat. Absence of 120V, when heating is required, indicates:  
a.) Power switch defective or OFF; or,  
b.) Temperature controller defective, or  
c.) Shorted temperature probe or probe wiring shorted (check between terminals 4 & 5); or,  
d.) Wiring or connector problem  
5.  
TP3 and TP4 are found only on waffle bakers equipped with a hi-limit thermostat. The hi-limit  
thermostat should be removed and bypassed to increase the reliability of the waffle baker.  
NOTE: Newer waffle bakers do not use a hi-limit thermostat. Existing hi-limit thermostats may  
be safely removed and bypassed without affecting the UL approval. See page 11.  
6.  
7.  
Voltage between timer terminals 2 & 3 is 120V any time the power switch is ON. Absence of 120V  
indicates:  
a.) power switch defective or OFF; or,  
b.) a wiring or connector problem  
Voltage between timer terminals 5 & 6 is 0V when the microswitch (item 10) is activated. Any  
voltage other than 0V indicates a defective microswitch, or a wiring or connector problem.  
8.  
9.  
Voltage between timer terminals 1 & 2 is 120V during the cook cycle. Absence of 120V indicates  
a defective timer module.  
An indicator light NOT lit when reading a voltage between timer terminals 1 & 2 is 120V indicates:  
a.) loose or defective wiring to the indicator light; or,  
b.) defective indicator light  
10.  
Voltage between timer terminals 2 & 4 is momentarily 120V at the end of the cook cycle.  
Absence of 120V indicates a defective timer module.  
5
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SERVICING INSTRUCTIONS  
CABINET  
SEAL  
INDICATOR  
SUPPORT BRACKET  
TRADEMARK PLATE  
RETAINER  
SWITCH  
SEAL  
GUARD  
ON/OFF PLATE  
BOTTOM  
PANEL  
RUBBER FOOT  
A.  
CABINET ASSEMBLY  
1. Insert the trademark plate from the front. From the rear of the cabinet, slide retainers over the  
trademark plate pins. Using a deep socket, tap the retainers down until they are flush with the  
cabinet surface.  
2. Attach wires 1, 2, 3 & 4 to the switch. Thread one nut onto the switch shaft approximately 1/2”, then  
slide the switch seal over the switch shaft. Insert the switch from the rear of the cabinet. Slide the  
guard, then the on/off plate over the switch shaft. Thread on and tighten the second nut.  
3. Work the seal over the body of the indicator light, then press the indicator into the cabinet until it  
pops securely into place.  
4. Install the support bracket.  
5. Screw four rubber feet into the bottom panel, then install the bottom panel onto the cabinet.  
6
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HOLE PLUG  
ASSEMBLY  
ALL GROUND  
WIRES  
CONNECT TO  
THIS STUD  
BUZZER  
POWER  
CORD  
STRAIN  
RELIEF  
THERMAL  
MASTIC  
HEAT SINK  
BACK  
PANEL  
FOAM  
TAPE  
TIMER  
TIMER BRACKET  
PC BOARD STANDOFF  
TEMPERATURE  
CONTROLLER  
ADJUSTMENT  
MODULE  
B.  
BACK PANEL ASSEMBLY  
1. Apply foam tape to the back panel flange - inside surfaces for the right, left and bottom; outside  
surface for the top.  
2. Insert the power cord into the strain relief, then install the strain relief from the outside of the back  
panel.  
3. From the outside, thread the ground wire of the hole plug assembly thru the large hole in the back  
panel. Tap the hole plug into place.  
4. Press the adjustment module onto pin 6 of the temperature controller and secure it with a dab of  
silicone sealant. Press the wire lead of the adjustment module onto pin 2. Coat both faces of the  
heat sink with thermal mastic (heat transfer compound). Slide the heat sink, then the  
temperature controller over the stud closest to the data plate embossing. The adjustment module  
should be oriented down and toward the outside.  
5. Insert four printed circuit board standoffs into the timer bracket. Push them until the button head is  
flush against the inside surface. Slide the bracket over the stud closest to the large hole, then  
secure with two screws from the bottom.  
6. Slide the buzzer over the same stud as the timer bracket.  
7. Lightly thread the nut onto the stud to retain the buzzer. Upon wiring the unit, after all ground wires  
have been attached to this stud, tighten the nut securely to ensure a positive chassis ground  
connection.  
7
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C.  
TOP GRID  
1. Prepare grid casting by applying a small amount of  
anti-sieze paste to all threaded holes.  
2. Feed wires 5, 6 & 20 thru the right feed-thru hole.  
Attach wires 5 & 6 to the element terminals. Attach  
wire 20 to the center-most boss at the front of the  
casting.  
3. Pull the wires back until they have only a small  
amount of slack. Seal both sides of both feed-thru  
holes with hi-temperature silicone sealant.  
4. Install the grid cover.  
D.  
BOTTOM GRID  
1. Prepare grid casting by applying a small amount of  
anti-sieze paste to all threaded holes.  
2. Set the grids waffle-side down, and with the rear  
portions touching. This positions the grids properly  
for later assembly.  
3. Feed the temperature probe leads and wire 10 thru  
the hi-temp tubing, then thru the left feed-thru hole.  
4. Feed wires 5, 6, & 20 (from top grid) and wires  
7 & 8 thru the right feed-thru hole. Attach wires  
5 & 8 to one element terminal, and wires 6 & 7  
to the other element terminal.  
see page 11  
5. Set the temperature probe between the two screw  
bosseswith its round nose pointing to the right.  
Slide the retainer over the probe. Install the screws  
with wires 10 & 20 attached to the center-most screw  
boss.  
8
5
7
6
HI-  
TEMP  
TUBING  
20  
10  
6. Route wires as shown. Pull the wires and hi-temp  
tubing back until they have only a small amount of  
slack. Seal both sides of both feed-thru holes with  
hi-temperaturesilicone sealant.  
TEMP  
PROBE  
7. Install the grid cover.  
PROBE  
RETAINER  
GRID  
8
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E.  
GRID ASSEMBLY  
1. Turn and position the grids so that the waffle-sides are facing each other. Thread the hi-temp tubing  
thru the shaft of the pivot housing. Attach the pivot housing to the bottom grid with screws (bottom  
hole) and screws with washers (middle hole). Use anti-sieze paste on the screw threads, but do  
not tighten the screws yet.  
2. Insert the pivot shaft thru the pivot housing and top  
grid, making sure wires 5, 6 & 20 are routed between  
the pivot shaft and the body of the top grid casting.  
Secure the pivot shaft with “C” clips on each end.  
HANDLE  
ASSEMBLY  
3. Verify that the top and bottom grids match at the  
mating surfaces, then tighten the screws securing  
the pivot housing to the bottom grid.  
4. Thread the brass bushing over hi-temp tubing and the  
shaft of the pivot housing. Press the bushing all the  
way against the face of the pivot housing.  
TOP GRID HINGE  
WIRING COVER  
5. Install the handle asembly in the top grid. Use  
BOTTOM GRID HINGE  
Loctite on the screw threads  
WIRING COVER  
TEFLON DRIP GUIDE  
6. Install the top grid wiring cover, then the teflon drip  
guide and bottom grid wiring cover. Use anti-sieze  
paste on the screw threads.  
7. The top grid should pivot smoothly. Gently bend the  
upper lip of the bottom grid wiring cover until the gap  
between wiring covers is maintained thru the entire  
swing of the top grid, and the top grid closes  
completely on the bottom grid.  
9
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F. PIVOT BEARING ASSEMBLY  
The pivot bearing may be out of alignment as it comes from the box. Tap the collar of the bearing  
with a plastic hammer until the axis of the bearing is perpendicular to the base. Attach the pivot  
bearing to the inside of the cabinet. The zerk fitting points downward. Use Loctite on the threads.  
1.  
2. Looking into the back panel, turn the bearing until the set screws are at the 10:00 and 2:00 position.  
Assemble the actuator to the pivot bearing. The set screws will protrude thru the holes on the  
actuator halves. The long arm of the actuator should point down, with the screws pointing left.  
3. Thread the wires of the grid assembly thru the pivot bearing from the outside, then insert the pivot  
housing shaft into the pivot bearing. Thread the actuator nut on the pivot housing shaft using  
Loctite on the threads. Tighten the pivot nut until the grid assembly rotates freely, but latches  
securely into the detent.  
4. If not already present, assemble the support  
bracket to the cabinet. Make sure the front of  
the grid assembly rides smoothly in the support.  
4. Rotate the grid assembly to the COOK position.  
Make sure the long arm of the actuator points  
straight down, then tighten the set screws.  
5. Using Loctite on the threads, assemble the  
microswitch to the switch saddle. Install the  
switch assembly into the cabinet. Adjust the  
position of the microswitch until a single CLICK is  
heard from the microswitch as the long arm of the actuator contacts the microswitch arm and the  
grid assembly rotates into the cook position detent.  
10  
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G.  
BYPASS HI-LIMIT THERMOSTAT  
1. The hi-limit thermostat in this Belgian Waffle Baker has been found to be unnecessary. Wells  
BWB-1S has been tested and approved by UL for use without the hi-limit thermosat.  
2. All units requiring service, whether in or out of warranty, should have the hi-limit thermostat  
bypassed.  
3. With the power cord unplugged, remove wires  
7 & 19 from the hi-limit thermostat (located in the  
bottom grid).  
7
7
4. Cut the push-on terminals from wires 7 & 19, as  
HI-LIMIT  
THERMOSTAT  
close to the terminals as possible.  
CERAMIC  
WIRE NUT  
5. Remove 1/2” of insulation from the ends of wires  
7 & 19. Connect the wires together using a ceramic  
wire nut of the appropriate size.  
6. Plug the waffle baker in, and test for proper  
operation.  
WIRING DIAGRAM  
CONNECTOR (2)  
POWER  
SWITCH  
4
L1  
L2  
white  
TEMPERATURE  
CONTROLLER  
1
2
3
black  
green  
10  
7
5
4
17  
8
POWER CORD  
INDICATOR  
LIGHT  
LOWER  
HEATING  
ELEMENT  
TEMP.  
SENSOR  
TIMER  
20  
6
5
13  
11  
12  
6
5
2
3
1
4
14  
MICRO  
SWITCH  
BUZZER  
N.C.  
UPPER  
COM  
HEATING  
ELEMENT  
15  
N.O.  
9
16  
VOLTS AMPS 1Ø  
p/n 44867 Rev.D  
120  
7.5  
50/60 Hz  
11  
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PARTS BREAKDOWN  
REF  
#
DESCRIPTION  
PART  
#
1
2
BOTTOM PANEL  
BACK PANEL  
3
5
WRAP, CABINET ASSEMBLY  
SWITCH SADDLE  
6
TRADEMARK PLATE  
7
8
9
RETAINER, TRADEMARK (pk 10)  
CORD, 125v 15a NEMA 5-15p  
DATA PLATE  
51038  
55539  
10  
12  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
27  
28  
31  
32  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
50  
62  
64  
65  
66  
67  
75  
76  
77  
78  
79  
SWITCH MICRO 120V 15A  
STRAIN RELIEF  
64887  
51217  
50222  
64872  
62257  
62028  
61064  
62029  
RETAINER RING (pk 10)  
PROBE, THERMISTOR, BWB-1S  
HANDLE ASSY BWB-1S  
BRACKET, FRONT SUPPORT BWB-1S  
HOLE PLUG ASSY  
COVER, BWB-1S  
ACTUATOR  
SPACER, BWB-1S  
PIN PIVOT UPPER HINGE, BWB-1S  
COVER, WIRING, UPPER BWB-1S  
COVER, WIRING, LOWER BWB-1S  
CONTROLLER,TEMPERATURE BWB-1S  
LIGHT, INDICATOR RED  
POP RIVET, 1/16 1/8  
SLEEVING, HI-TEMP (8.5")  
BEARING, BWB-1S  
HOUSING ASSY, PIVOT  
RUBBER FEET, (pk 4)  
GRID & ELEMENT, LOWER BWB-1S  
GRID & ELEMENT, UPPER BWB-1S  
NUT, PIVOT HOUSING  
TIMER BRACKET  
STANDOFF, PC BOARD BWB-1S  
BUZZER  
62035  
62018  
62023  
62031  
64276  
60758  
64201  
62232  
62006  
21657  
62007  
62008  
63565  
60529  
63179  
TIMER, ELECTRONIC, BWB-1S  
LABEL, DO NOT IMMERSE  
SEAL, O-RING, SIGNAL LIGHT  
ON-OFF PLATE  
64890  
53192  
SWITCH GUARD  
SWITCH, TOGGLE W/SEAL  
HOLDER, PROBE BWB-1S  
DRIP TRAY, BWB-1S  
64904  
64885  
21107  
FOAM TAPE  
HEAT TRANSFER COMPOUND (THERMAL MASTIC)  
HEAT SINK  
TEFLON DRIP GUIDE  
66160  
502900  
503523  
NOT SHOWN:  
WIRING DIAGRAM BWB-1S  
44876  
64917  
502863  
WIRESET BWB-1S (OVER HEATED OR RUNAWAY TEMP DAMAGE)  
ELEMENT JUMPER WIRESET ONLY  
12  
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BWB-1S BELGIAN WAFFLE BAKER  
EXPLODED VIEW  
21 44  
5
39  
10  
32  
22  
20  
67  
16  
42  
79  
25  
24  
40  
19  
12  
8
2
76  
47  
45  
48  
23  
15  
43  
17  
50  
20  
18  
31  
9
3
76  
62  
28  
46  
27  
7
6
77  
78  
65  
64  
66  
1
75  
41  
13  
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IMPORTANT: WELLS MFG. PROPRIETARY INFORMATION  
TECHNICAL CONTENT OF THIS MANUAL IS DESIGNED FOR  
USE BY QUALIFIED PROFESSIONAL TECHNICIANS ONLY  
WELLS MANUFACTURING COMPANY  
2 ERIK CIRCLE, P. O. Box 280  
Verdi, NV 89439  
Service Parts Dept. (888) 492-2782  
fax: (888) 492-2783  
service@wellsbloomfield.com  
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