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We've got the same problem and I just took ours apart.
Bad news: I'm pretty sure it's the circuit board. It's not the timer knob, and I'm almost positive it's not the upper selector knob. Most of the components on the circuit board are only used for the "bake" mode to regulate temperature. The board is marked, "128301 Timer PCB". I looked into whether one can buy a replacement board from Kitchenaid, but it's not on their parts list. If I had to guess, I'd say it's the relay on the board, but it's only a guess. Shoddy components, plus it gets hot in there and "bakes" the board. The little fan in the side isn't part of the "convection." It's for cooling off the circuit board. Don't laugh.
Even worse, next to the thermostat on ours, there's a little rubber insulator that's burnt to a crisp. The connection under this insulator was also loose. It hasn't affected functionality, but it doesn't instill confidence in the design. Kind of scary. Unplug this unit when not in use!
Only a one year warranty. I think we now have an expensive toaster.
You are correct in your diagnosis. The selection switch has 2 sets of contacts that should only make one when on bake. The contacts internal to that fuse are most likely fused together, the other thing that could be going on is a short circuit in the wires to the selection switch causing the same problem. Typically a repair unless under warranty would be costly unless you are up for the challenge of replacing the switch and checking the wiring yourself.
YES YOU ARE your trying to bake something in a toaster oven :) toaster ovens have two modes toast /bake in this mode top and bottom elements get hot .and broil in this mode only the top elements get hot . the problem is the marketing the word OVEN makes you think of a normal oven that the bottom elements do all the work . toaster ovens work well melting stuff and toasting . thats about it . if you must bake in it try placeing a sheet of foil on top of your baked goods it might insulate the top of you food . good luck ... if this answer helped please rate it a 3 or 4 stars , this high rateing will help keep me in the paid answer department , thank you
you are correct . it is the convection . the fan blows the air around and away from the elements ,when that is happening the elements can never get hot enough to glow , as the oven gets hotter and at some point the air is so hot even with it blowing the elements will start to get red ... this is good because todays elements are thin and cheep and melt easy so the fan keeps the heat away from them and the elements last longer ...... if this answer helped please rate it a 3 or 4 stars .this high rate will help keep me in the paid answer department ... thank you
its not repairable at any price . you have a bad thermostat , its soooooo common with this oven . asprie who makes this oven in china, then inports it with black & deckers name on it . has not made any parts for it , not even a wire shelf or a knob .....when something happens to it , you toss it in the trash .....