Hottop Repair procedure - Fusible Link Replacement/Update

Repair Procedure Fusible Link Replacement/Update Click on the small images on this page to see a higher-resolution version of the image. The larger image will open in a new window that can be closed after viewing

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: Front Cover Bearing Plate and Drum Remove Fan Remove Rear Cover Remove Top Cover

1		Cut the two tie wraps holding the wire bundle above the Main Circuit Board together. Discard the clippings (Do not leave them in the machine).

2a		Examine the Main Board terminals T3 and T4. If you find a resistor jumper between terminals T3 and T4 you have the current update installed. You must CLICK HERE to continue with the replacement of the Fusible Link. Otherwise, examine Step2b below:
2b		Examine the main Board terminals T3 and T4. If there are two wires covered with a woven insulation as shown here then you have the older style fusible link and will be installing the updated Fusible Link as the old style is no longer available. Continue with Step 3 below. 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.

3		Use a needle nose pliers to remove the two wires shown here which connect the Fusible Link to the Main Circuit Board. Your board may look different from that shown here, but the terminal numbers on the Main Board are T3 and T4.

4		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.

5		Remove the screw holding the Fusible Link's bracket to the roasting chamber's rear wall. Remove the fusible link from the machine.

6		Remove one of the two wires connected to the heating element. You can remove either one. If one wire looks a little worse for wear than the other, choose that one. Trace the wire down through the Dividing Plate to the Main Board below, and remove its other end which is attached to either terminal T5 or T6 depending on which wire you chose. Remove the wire from the roaster. It will no longer be needed.

7		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.

8		Loosely attach the new Fusible Link to the roaster using the same hole, but use the new screw included with the kit. Be sure that the fusible link sits flat against the back wall of the roasting chamber and that no wires are trapped under the new link.

9		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. make sure that the link is firmly up against the metal plate that is the rear wall of the roasting chamber. 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 described above. Failure to assure that this is done correctly can create a fire hazard! Be sure to locate the fusible link away from the heating element.

10		The Fusible Link has two wire leads. The short lead with the woven insulating cover attaches to the heating element. One wire is already attached to the heating element. The Fusible Link wire attaches to the other heating element lead. It does not matter which of the two heating element terminals you use for the Fusible link. The arrow here indicates that in this 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 using a pair of pliers, squeeze the spade clips at the end of the wires closed a bit and check their fit once again. Use caution when pushing on the heating element's attachment points.

11		Terminals T3 and T4 are vacant at this time from the removal of the original Fusible link. The jumper resistor that was included with the update kit is attached to these two terminals as shown here. The use of a pair of small needlenose pliers is recommended. Grasp only the spade connectors under the black insulation. DO NOT push on the resistor nor its leads directly as they may be damaged.

12		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.

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