Merrychef 402s Service & Parts Manual
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Merrychef 402s Service & Parts Manual

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Version 3.0
Version 2.0
Merrychef
402s
US Models including WAWA
S E R V I C E & P A R T S M A N U A L
This manual covers US models manufactured from:
ISSUE 6
Version 2.0 Serial No. 000745 –001199
18.03.2008
Version 3.0 Serial No. 001200 onwards
CAUTION MICROWAVE EMISSIONS
DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE
GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY
402s Ovens Pt. No. 32Z3522 Issue 6
1

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  • Page 1 ISSUE 6 Version 2.0 Serial No. 000745 –001199 18.03.2008 Version 3.0 Serial No. 001200 onwards CAUTION MICROWAVE EMISSIONS DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 2: Table Of Contents

    Appendix 5: PCB connection Points ........ 43-44 Appendix 6: Engineering Test Settings........45 Appendix 7: Firmware revision guide....... 46-51 Merrychef USA 1111 North Hadley RD Fort Wayne IN 46804 Phone: 800/678 - 9511 Fax: 800/285 - 9511 e-mail: info@merrychefusa.com 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 3: Microwave Safety Precautions

    For CANADA. (ii) A microwave leakage check to verify compliance with the Canadian Regulation, HEALTH AND WELFARE, SOR/79 920 should be performed on each oven prior to release to the owner. 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 4: Safety Code

    SAFETY CODE This manual is designed to assist engineers who have been on a recognised product familiarisation and training course run by Merrychef. It has been prepared to offer technical guidance for the 402s range of Ovens. Please remember that it is wiser not to attempt a service task if you are unsure of being able to complete it competently, quickly, and above all safely.

  • Page 5: Product Specifications

    PRODUCT SPECIFICATIONS Model Number: 402S VVV F P C R TT ZZ Example 402S2086DK3GMUS Model No. EC402s 208V, 60Hz, 2P + GND supply, MenuKey Revision 3, General Market, USA Supply Freq. Control Country Phase/Supply Type Voltage Type /Region Voltage (ac)

  • Page 6: Installation Instructions

    ALWAYS Place containers in the cavity carefully - impact damage may chip the vitreous enamel coating on the runners and Note: baffle plate. The minimum recommended clearance required for air flow 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 7: Main Features

    STEAM VENT PIPE g RATING PLATE Vents steam from the oven cavity The rating plate is situated on the rear of the oven, and states the Model, Serial Number, Electrical Ratings and Manufacturers telephone number. 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 8: Main Features

    Indicates combustion ( fire ) in more than 90°F above oven cavity PREHEAT temperature Note: In service operations when setting during cook cycle PREHEAT is set to 0°F this message can appear when the oven is operated 402s Ovens Pt. No. 32Z3522 Issue 6...
  • Page 9 Restricted airflow to air filters Combustion (fire) in cavity Heater Failure Cavity has not reached a One or more heater elements have failed temperature of 100°F in 10 minutes and need to be replaced 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 10: Principal Components: Rhs

    Microswitch Assembly SA212 Door Hinge Assembly RH SA202 Magnetron Cooling Fan 30Z1295 HV Capacitor 2500V 0.88μF ( 60HZ models ) 30Z1251 HV Capacitor clip 31Z1261 Fibre Optic Diode Board 11M0364 Solid State Relay 30Z1362 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 11: Principal Components: Lhs

    30Z1294 Microswitch SW4 Microswitch Assembly SA212 Door Hinge Assembly LH SA203 Motor Controller 30Z1293 HV Capacitor 2500V 0.88μF ( 60Hz models ) 30Z1251 25A HV Capacitor clip 31Z1261 Fibre Optic Diode Board 11M0364 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 12: Principal Components: Top

    Ribbon Cable 10way MenuKey 11M0117 Logic PCB Assembly Version 2.0 SA231 Logic PCB Assembly Version 3.0 SA260 Transformer LT (Low voltage) 30Z1155 Fuse 1A 30Z0957 Sounder SA257 Fibre Optic Logic PCB 11K0013 Relay PCB Fuse 30Z0470 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 13: Principal Components: Back View

    ( Each magnetron) Convection ( Hot Air ) Motor Assembly SA208 Thermistor Cavity 30Z1315 Transformer 208/220/240V 60Hz 30Z1230 HT Rectifier (No Fibre Optic) 11H0010 Magnetron Cooling Duct LH DV0039 Magnetron Cooling Duct RH DV0040 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 14: Principal Components: Power Supply

    Filter 16A 30Z1340 Fuse 10A HRC 30Z0217 Cable Gland 31Z0500 Cable Gland Nut 31Z0499 Electrical Supply Lead Assembly SA217 Terminal Block 31Z0447 Fuse 20A FLM 30Z1177 Fuse Holder 30A 30Z1178 Fuse Holder 10A 30Z0231 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 15: Principal Components Cavity Parts

    * Parts 35 & 37 Contact Service Department KFC Accessories 65 Chicken Griddle SA133 Description Part No. Cool-down pan 32Z4028 Oven tray MC3175 Handle SA267 Griddle DV0221 Griddle carrier SA350 Chicken Griddle (SA350 + DV0221 + DV0267) SA133 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 16: Principal Components: External Panels

    31Z3094 Door Handle spacer DV0309 *Note: On Ovens with Serial No.s before 000745 ( WAWA Models ) External Panels Items 41,42, 43, 45, 47,48, 50, 51, 52 are only available to special order. 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 17: Principal Components: Control Panel

    DV0192 Front Panel Version 2.0 DV0036 Display Assembly & Header Version 2.0 30Z1299 MenuKey Socket 11K0005 GM Membrane Version 3.0 DV0254 Front Panel Version 3.0 DV0249 Display Assembly & Header Version 3.0 30Z1324 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 18: Parts Matrix

    Transformer 208/220/240V 60Hz 11H0010 HT Rectifier SA217 Electrical Supply Lead Assembly 31Z0447 Terminal Block Fuse 20A FLM 30Z1177 30Z1178 Fuse Holder 30A Fuse Holder 10A 30Z0231 Grease Filter ( 2 parts ) SA339 SA340 402s Ovens Pt. No. 32Z3522 Issue 6...
  • Page 19 Cage Nut (Door Choke Plate) 31Z3094 Screw M3 Csunk ( Doorskin) Door Handle spacer DV0309 31Z0527 — Stirrer cover sealant ( tube ) SA340 — Grease Filter Cartridge — Microswitch interlock spring 31Z1247 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 20: Procedure For Microwave Emission Test

    Check for radiation emission after servicing. Should the emission be more than 4mW/cm² Inform Merrychef service centre immediately. After repairing or replacing any radiation safety device, keep a written record for future reference, as required by D.H.H.S. and Health and Welfare Canada regulation.

  • Page 21: Procedure For Microwave Emission Test

    • Readings must be below 4mW/cm². If a level greater that 4mW/cm² is observed, this should be reported to Merrychef Service Division immediately. • In any case, notes should be kept of the leakage that is observed. In terms of level and position on the oven.

  • Page 22: Procedure For Power Output Measurement

    27ºF ( 15ºC ) Minimum 36ºF ( 20ºC ) Maximum Note: Power Output is affected by the line voltage under load. For correct Power Output measurement the line voltage under load must be correct. 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 23: Procedures For Principal Component Tests

    2. Ensure that the High Voltage Capacitor is discharged before commencing work. 3. Remove all connections from the High Voltage Capacitor. 4. Using a D.M.M., check for continuity between the terminals & compare results with table on next page. 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 24: Procedures For Principal Component Tests

    3. Remove all connections from the Magnetron. 4. A continuity check across the Filament terminals should be 1ohm or less 5. A continuity check between each filament terminal and the metal outer should read open. 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 25: Procedure For Door Interlock Adjustment

    PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST 1 The door on the 402s oven is monitored by four microswitches. Three are used in the conventional “Primary, Secondary and Monitor” switch arrangement shown below and the fourth sends a signal to the Logic PCB. The switches operate as follows:...

  • Page 26: Procedure For Door Interlock Adjustment

    5mm spacer in the same position. Check that SW2 and SW3 are open circuit and not operated. Repeat the steps above to ensure the setup is correct. Ensure that all the screws are tightened. Reconnect the electrical supply. 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 27: Hot Air Motor And Controller

    Part No. Heater Element 208V 650W 68Ω DV0328 DV0337 Heater Element 240V 650W 88Ω Heater Element Collar DV0058 Convection ( Hot Air ) Motor Assembly SA208 Gasket Set SA332 8x 31Z4016 M5 Flange nut 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 28: Hot Air Motor And Controller

    Inverter Off / No supply Long On & Off (1sec) Power On / Ready LED On steadily Inverter Running Long On (0.5 sec)/ short Off General Warning Very Short On & Off (0.1sec) Fault Condition 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 29: Wiring Diagrams

    402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 30: Trouble Shooting Guide

    • Cavity Sensor Error Page 33 • Magnetron / Over heat errors Page 34 Note : The following Diagnosis procedures may not expose all possible errors but have been included for general guidance. 402s Ovens Pt. No. 32Z3522 Issue 6...
  • Page 31 Still Have a Problem? Spare Display Still Dead works Replace Display Check Connection Output at Aux Transformer. Check Power supply to Relay PCB Check Fuse on Relay PCB Still Have a Problem? Replace Logic PCB 402s Ovens Pt. No. 32Z3522 Issue 6...
  • Page 32 Check that the stirrer is rotating. Carry out Microwave Output Test Replace stirrer motor and retest Check Microwave Generating system Contact Merrychef Service Department for Further • Transformer assistance. • Magnetron • Capacitor • Diode 402s Ovens Pt. No. 32Z3522 Issue 6...
  • Page 33 1. The cavity did not heat by 180°F in the 10 Minutes Replace Sensor 2. The cavity exceeded the set point when cooking by more than 72°F whilst cooking which indicates that the food load was on fire 402s Ovens Pt. No. 32Z3522 Issue 6...
  • Page 34 High Voltage in More than Temperature the magnetron area. 110°F reading Check sensor connections. Replace Magnetron. Cooling Air Flow Check 15 ribbon Cable Problem into control area. Replace Relay PCB. Ambient Conditions too hot 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 35: Appendix 1: Temperature Probe

    3.434 0.950 1.000 1.050 0.3572 0.3865 0.4171 R(200)°C = 1 kΩ ± 5% Note: These resistances will only be apparent in a stable cavity temperature as the sensor has a slow response time. 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 36: Appendix 2: Menukey Procedures

    Oven Model No. Software & MenuKey serial No. OVEN COLD Model No. 402S PRESS PREHEAT The standby screen will then Software MK serial No. display Remove the MenuKey and keep in a safe place. 402s Ovens Part. N 32Z3522 Issue 6...
  • Page 37 Copying Programs from Verifying Programs MenuKey Copied Oven to MenuKey Copied Correctly Successfully The Display returns to the CATEGORIES screen and the Oven will heat up to the PREHEAT temperature ready to cook. 402s Ovens Part. N 32Z3522 Issue 6...
  • Page 38 OVEN HOT PLEASE WAIT PLEASE WAIT ( Also in Spanish) Cycle ends COOL DOWN COMPLETE Turn oven off and ensure READY FOR CLEANING Air Filters are clean Switch oven off ready for cleaning 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 39: Appendix 3: Cleaning Procedure

    Oven Protector onto the surfaces of the oven surface of the oven door erating temperature it will sponge take 30 minutes to cure the Oven Protector. Note: oven protector turns light brown when cured 32Z3522 Issue 6 402s Ovens Part. N...
  • Page 40 WARNING: DO NOT use caustic cleaners on any part of the oven or oven cavity as it will cause permanent damage to the Catalytic Convertors Equipment: Merrychef oven cleaner, Merrychef Oven Protector, heat proof gloves, protective rubber gloves, non–abrasive nylon scrub pad, cleaning towel and cloths, eye protection and dust mask (optional)

  • Page 41: Appendix 4: Recommended Spares List

    SIDE PANEL RH DV0094 TOP TRIM - V1 DV0168 DOOR CHOKE (PRESSED) DV0187 TOP PANEL (PRESSED) DV0192 WAWA MEMBRANE DV0203 SEAL - CERAMIC COVER DV0254 402s MEMBRANE V3 DV0275 RACK V3 DV0305 DOOR SEAL 402S 402s Ovens Pt. No. 32Z3522 Issue 6...
  • Page 42 CATALYST ASSY UPPER (V1 - V2.5) SA315 CATALYST ASSY LOWER V1 - V2.5) SA329 REAR PANEL SA332 GASKET SET SA339 GREASE FILTER HOUSING SA340 GREASE FILTER CARTRIDGE SA351 CATALYST ASSY UPPER (V3) SA353 CATALYST ASSY LOWER (V3) 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 43: Appendix 5: Pcb Connection Points

    MenuKey Sockect Connector Program Motor speed D7 Power LED memory storage. controller Indicates Logic PCB May be is powered exchanged See Troubleshooting with New PCB if Guide Membrane panel PCB replaced. connector 402s Ovens Pt. No. 32Z3522 Issue 6...
  • Page 44 Inputs D20 LED when power is on Connector To when Microwave is Logic PCB operated. U1 Ambient air temperature sensor Display Fuse Fuse Not Used AC input from Aux Transformer Piezo sounder output 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 45: Appendix 6: Engineering Test Settings

    OVEN COLD/PRESS PREHEAT To display the Manual mode screen. standby screen press the PREHEAT/ COOL DOWN pad on the control panel and then press Manual. READY TO COOK AT 000ºF Manual Run Prog 402s Ovens Pt. No. 32Z3522 Issue 6...

  • Page 46: Appendix 7: Firmware Revision Guide

    APPENDIX 7: Firmware revision guide. As a result of on-going changes / upgrades to the 402s Oven, this Appendix has been produced stating the following: 1.0 An overview of the control system for a 402s. 2.0 How to check your Firmware version 3.0 How to check your hardware fitted...
  • Page 47 Subway and KFC Note: ALL ovens that are lower than 3.0LD Firmware should be up-lifted to version 3.0LD or higher depending on what hardware is fitted. (Refer to Table 2a & Table 2b) 402s Ovens Pt. No. 32Z3522 Issue 6...
  • Page 48 Pin strip fitted but no optics board TABLE 2B Hardware Upgrade Technical Bulletin Required V2.5 oven oven oven Hardware Upgrade Adding Magnetron Detect TB114 TB114 Adding Solid State Relay TB122 TB122 402s Ovens Pt. No. 32Z3522 Issue 6...
  • Page 49 3.0LD or higher Fibre Optics Board + leads fitted TABLE 2b: Hardware Upgrade Technical Bulletin Required V2.5 oven oven oven Hardware Upgrade Adding Magnetron Detect TB114 TB114 Adding Solid State Relay TB122 TB122 402s Ovens Pt. No. 32Z3522 Issue 6...
  • Page 50 PAUSE pad to hold the oven information screen. OVEN INFORMATION Oven On Time: 00028 Hours Magnetron On Time: 00000 Hours Door Operations: 00049 Software Version: 4.0LD MenuKey Code: MenuKey Checksum F076 PAUSE>> PAUSE pad 402s Ovens Pt. No. 32Z3522 Issue 6...
  • Page 51 Copying Programs from Verifying Programs MenuKey Copied Please Wait MenuKey to Oven Copied successfully Successfully The display will show the start up sequence and the Oven will begin heating up. Remove the MENUKEY 402s Ovens Pt. No. 32Z3522 Issue 6...

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