Merrychef Mealstream 500 Service Manual
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Merrychef Mealstream 500 Service Manual

Merrychef Mealstream 500 Service Manual

Combination microwave ovens
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Merrychef
Mealstream 500
S E R V I C E
M A N U A L
Part No. 32Z3387 Issue No.3
For all Mealstream 501, 502 & 503 models manufactured
from January 2001 & Tim Hortons Models
CAUTION MICROWAVE EMISSIONS
DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE
GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY
Mealstream Ovens 32Z3387 Issue 3
Page 1

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Summary of Contents for Merrychef Mealstream 500

  • Page 1 Merrychef Mealstream 500 S E R V I C E M A N U A L Part No. 32Z3387 Issue No.3 For all Mealstream 501, 502 & 503 models manufactured from January 2001 & Tim Hortons Models CAUTION MICROWAVE EMISSIONS...

  • Page 2: Table Of Contents

    Manual corrections and modifications .........53 Merrychef Limited, Station Road West, Ash Vale, Aldershot Hampshire GU12 5XA United Kingdom Tel: +44 (0)1252 371000 Fax: +44 (0)1252 371007 Internet address: http://www.merrychef.com E-mail: sales@merrychef.com or service@merrychef.com Mealstream Ovens 32Z3387 Issue 3 Page 2...

  • Page 3: Safety Code

    This manual is designed to assist engineers who have been on a recognised product familiarisation and training course run by Merrychef Limited. It has been prepared to offer technical guidance for the Merrychef Mealstream 501 range of Combination Microwave Ovens.

  • Page 4: Product Specifications

    Product specifications: Model Number: CTMx v f c p MK C Example CTM524505MK Mealstream EC501, High speed fan 230-240V, 50Hz, Series 5 electronic controls & MenuKey CTMx Fan Speed Voltage Frequency Control Type Phase MenuKey Catalytic Converter CTM3 = 22 = 220-230V EU 50 = 50 Hz 5 = Electronic 2 = 2 phase...

  • Page 5: Installation Instructions

    Installation Instructions for Mealstream 500 series Combination Ovens Power Supply Requirements The Mealstream 500 series oven should be connected to a suitable electricity supply, which can cope with the switching-on surge that occurs with certain types of catering equipment, such as microwaves.

  • Page 6: Error Codes And Diagnostics

    Error codes and diagnostics Models with electronic controls identify some of the most common problems by flashing an error message code in the time display window. Error Message Possible Cause Service Door not fully shut Close door fully Possible electrical fault Check Microswitch Door Circuit Check Microswitch Connection to PCB Check Ribbon Cable...

  • Page 7: Main Features

    Main features: back panel a On/Off SWITCH f HOT AIR FAN This is used to turn the oven On or Off. Situated behind the baffle plate, and circulates the hot air through the baffle plate, over the IT DOES NOT ISOLATE INTERNAL WIRING heating element, and around the edge of the FROM THE MAINS SUPPLY.

  • Page 8: Electronic Controls

    Electronic controls: Stage LED's Program & Time Display Service Indicator Air Filter Block Indicator Convection Pad Power Pads Time / Program Number Pads Temperature Set Pads Cancel / Callback Pad Program Pad MenuKey socket Mealstream Ovens 32Z3387 Issue 3 Page 8...

  • Page 9: Manual Controls

    Manual controls: TEMP °C POWER % TIME START merrychef Mealstream CD Power Neon ( Amber ) Temperature Control Power Control Timer Start Push button Cook cycle Neon ( Red ) Heater Neon ( Amber ) Mealstream Ovens 32Z3387 Issue 3...

  • Page 10: Power Output Testing To En 60335-2-90

    Procedure A - Power Output Test in accordance with BS EN 60335-2-90 Annex AA This test is given in the BSI test standard for microwave ovens. It is reproduced below - not so that you can follow it, but to show you why it is impractical in normal conditions. A simplified procedure, which gives a good approximation to the BSI power output, is given in Procedure B which follows.

  • Page 11: Power Output Testing

    Procedure B - Simplified Power Output Test You will need: A thermometer capable of reading to ±0.1°C. For Tim Hortons A Polypropylene tray approximately 200 mm x 200 mm. see APPENDIX 8 A measuring jug. A calculator. Water which is at a temperature of 10°C ± 2°C. Measure 1 litre of cold water into the tray using the measuring jug.

  • Page 12: High Voltage Capacitor Test

    Procedure D - High Voltage Capacitor Test You will need: A Digital Multi-meter (D.M.M.) A Megger or similar resistance meter using 500V d.c. WARNING: High voltages and large currents are present at the High Voltage Capacitor. It is very dangerous to work near this part when the oven is on. NEVER make any voltage measurements at the High Voltage circuits, including the magnetron filament .

  • Page 13: Principal Components Lhs

    Principle components: Left side Description EC 501/2/3 RD 501 Fuse holder 30Z0231 30Z0231 Fuse 10 amp 30Z0217 30Z0217 Fuse holder 30Z0231 30Z0231 Fuse 10 amp 30Z0217 30Z0217 Fuse holder 30Z0231 30Z0231 Fuse 1 amp 30Z0957 30Z0957 Fuse holder 30amp ( FLM Series ) 30Z1178 30Z1178 Fuse 20 amp Littlefuse FLM020...

  • Page 14: Principal Components Rhs

    Principle components: Right side Description EC 501/2/3 RD 501 520000 520000 Door spring short 40C1141 40C1141 Door spring long 11C0279 11C0279 Door arm stop assembly Door arm assembly 11C0300 11C0300 Door hinge assembly ( RH ) 11C0166 11C0166 Microswitch ( Secondary ) 30Z0240 30Z0240 Steam pipe...

  • Page 15: Principal Components Top

    Principle components: Top view Description EC 501/2/3 RD 501 Magnetron 30Z0264 30Z0264 Resistor Gold 470 R 30Z0283 30Z0283 HT diode 11C0266 11C0266 Capacitor 1.1µF 30Z1077 30Z1077 Transformer 220V 50Hz 30Z0083 30Z0083 Transformer 240V 50Hz 30Z1018 30Z1018 Twin blower motor 310110 310110 25mm OD Flexible conduit 314402...

  • Page 16: Principal Components Cavity Roof And Door

    Principle components: Door & cavity roof Note: for Tim Hortons see Appendix 8 Description EC 501/2/3 RD 501 Stirrer glass & long seals 40C0954 40C0954 Stirrer glass short side seal 790052 790052 Door seal kit 11C0292 11C0292 Door choke 790007 790007 Air Filters Description...

  • Page 17: Principal Components Cavity

    Principle components: Heater Element, Catalytic Converter & Cavity parts: CTM5_, [EC501] CTM5_, [EC502] CTM5_, [EC503] CTM3_ [EC501, RD501] Description Part No. Heater element (2.5kW) 40C0954 Heater element (3.0kW) 40C0948 Heater element cover plate 790047 Baffle 11C0311 Dome Nut 80X7025 Shelf Support 40C0950 Hot Air Impeller MC3703B...

  • Page 18: Principal Components ( Not Shown In Main Views )

    Principle components: ( not shown in main views ) Left Hand Door Hinge Right Hand Door Hinge Assembly Assembly (Includes all parts shown) (Includes all parts shown) Stirrer motor assembly Hot air motor: Hot air motor: High Speed Low Speed Motor shaft screen and seal assembly Description...

  • Page 19: Input Wiring

    Input wiring details Green/Yellow Blue Brown Part No. Description Mains Terminal Block 31Z0149 Cable Gland 31Z1070 Gland Nut 31Z1082 Mains Cable 3 Core 31Z0148 High Speed Hot Air Motor [CTM5] connections and wiring Mealstream Ovens 32Z3387 Issue 3 Page 19...

  • Page 20: Interlock Operation

    Door interlock operation The door on the oven is monitored by three microswitches. These are used in the conventional “Primary, Secondary and Monitor” switch arrangement shown below. The switches operate as follows: Door Interlock Arrangement Secondary switch Primary switch Power Out Power In Monitor switch The diagram shows the microswitches in door closed position...

  • Page 21: Electronic Control Panel Assembly

    Electronic control panel assembly: EC501, EC502 & EC503 Part No. Description On/Off Switch 30Z0503 Control Panel Assembly (without MenuKey) 11C0294 Control Panel Assy with MenuKey 11C0438 Locare Control Panel Assy with MenuKey 11C0458 Logic Board (without MenuKey) 11C0291 Logic Board with MenuKey 11C0377 Relay Board 11C0212...

  • Page 22: Manual Controls Panel Assembly

    Manual control panel assembly: RD501 Description Part No. On /off switch 30Z0503 ac voltage connector 6 way 11M0116 dc voltage connector 10 way 11M0117 PCB Assembly 11C0295 Red Neon 316030 Timer 30Z0991 Potentiometer 5k 40C0892 Amber Neon 316031 Panel assembly 11C0307 Pushbutton 31Z0349...

  • Page 23: Membrane Panel Circuit

    Membrane panel circuit You will need: A Digital Multi-meter (D.M.M.) 1. Isolate the oven from the mains supply. 2. Remove the Logic Assembly from the Control Panel Housing. 3. Unplug the membrane “tail” from the Logic PCB Assy. 4. Using a D.M.M., check for continuity between the correct terminals when the pads are pressed.

  • Page 24: Complete Spare Part Listing

    Part number identification chart: Description EC501/2/3 RD501 Fuse holder 30Z0231 30Z0231 Fuse 10 amp 30Z0217 30Z0217 Fuse holder 30Z0231 30Z0231 Fuse 10 amp 30Z0217 30Z0217 Fuse holder 30Z0231 30Z0231 Fuse 1 amp 30Z0957 30Z0957 Fuse holder 30amp ( FLM Series ) 30Z1178 30Z1178 Note B: see APPENDIX 7...
  • Page 25 Part number identification chart: Description EC501/2/3 RD501 PCB Assembly ——— 11C0295 Red Neon ——— 316030 Timer ——— 30Z0991 Potentiometer 5k ——— 40C0892 Amber Neon ——— 316031 Panel assembly ——— 11C0307 Pushbutton ——— 31Z0349 Control knob Red/Grey ——— 11C0173 Control knob Blue ———...

  • Page 26: Electrical Diagrams

    Circuit diagram: EC501, EC502, EC503 Mealstream Ovens 32Z3387 Issue 3 Page 26...
  • Page 27 Circuit diagram: RD501, CTM3__CD2 Mealstream Ovens 32Z3387 Issue 3 Page 27...

  • Page 28: Appendix 1: Menukey Download Procedure

    APPENDIX 1: MenuKey Download Procedure The MenuKey™ System automatically changes all the cooking programs on the numbered icon pads with the turn of a key. To change the menus on the oven: Ensure the power switch is off. Lift the MenuKey cover in the front panel of the oven and put the key in the keyhole...

  • Page 29: Appendix 2: Cleaning Procedure

    APPENDIX 2: Cleaning procedure Mealstream 501 For the oven to operate at peak efficiency, the cavity, door and the air filters must be kept clean. A daily cleaning routine will ensure that you comply with the required hygiene standards and will help to maintain and prolong the efficiency of your oven. Follow the SAFETY INSTRUCTIONS at the beginning of this manual.

  • Page 30: Appendix 2: Cleaning Procedure

    APPENDIX 2: Cleaning procedure Mealstream 502, Mealstream 503 For the oven to operate at peak efficiency, the cavity, door and the air filters must be kept clean. A daily cleaning routine will ensure that you comply with the required hygiene standards and will help to maintain and prolong the efficiency of your oven.

  • Page 31: Appendix 3: Pcb Connection Points

    APPENDIX 3: PCB Connection Points and key features, EC501, EC502 & EC503 Cavity sensor 11C0291 Issue 5 50E123 Relay PCB Relay PCB °C Link Mealstream Ovens 32Z3387 Issue 3 Page 31...
  • Page 32 APPENDIX 3: PCB Connection Points and key features EC501, EC502 & EC503 Menukey 11C0377 Issue 2 Temperature Calibration Relay PCB Relay PCB °C Link Mealstream Ovens 32Z3387 Issue 3 Page 32...
  • Page 33 APPENDIX 3: PCB Connection Points and key features EC501, EC502 & EC503 11C0212 Issue 11 Relay PCB Transformer 1 (LHS) Transformer 2 (RHS) Soft start common relay Heater switch Return from door switch & 0H Mag stats Neutral Live Earth Mealstream Ovens 32Z3387 Issue 3 Page 33...

  • Page 34: Appendix 4: Transformer Upgrade

    APPENDIX 4: Transformer Upgrade In partnership with our supplier Tabuchi, we have developed a multi-tap transformer that will output 208V, 220V & 240V. There are 2 models for 50Hz and 60Hz power supply. Should you need to change a transformer to any Mealstream 501 product, you should use the new 30Z1233 ( 50Hz power supply ) or 30Z1230 ( 60Hz power supply) multi-tap transformer, see matrix below.

  • Page 35: Appendix 5 Hot Air Motor Replacement

    APPENDIX 5: Hot air motor replacement procedure 1 we have improved the hot air motor assembly by enhancing the wave trap and balancing the impeller which is now fitted by a grub screw to a flat on the shaft. The tolerances to manufacture the motor shaft have also been tightened to improve the fit of the balanced impeller.
  • Page 36 APPENDIX 5: Hot air motor replacement procedure 2 Step 9 Fit new wave trap Pt. No. 40C1201 to cavity. See figures 1(a) & 1(b) (Making sure it is centred in the hole) Ensure wave trap is fitted correctly and not caught around the edge of the hole. See figure 2 Figure 1(a) Figure 2...
  • Page 37 APPENDIX 5: Hot air motor replacement procedure 3 Step 10 Fit new hot air motor assembly Pt. No. 11C0472 (see diagrams below) Make sure the motor shaft is centred in the hole A) Fit motor assembly Pt. No. 11C0472 and secure finger tight with flange nuts & washers.
  • Page 38 APPENDIX 5: Hot air motor replacement procedure 4 Adjusting alignment procedure Figure 6 To ensure correct alignment of the assembly there are 2 procedures that may be required: Procedure 1 Loosen x4 The 4 bolts holding the wave trap to the cavity need to be loosened off sufficiently to allow movement of the wave trap.
  • Page 39 APPENDIX 5: Hot air motor replacement procedure 5 Step 11 With the alignment correct Reconnect motor wires at terminal block. See figure 9a & 9b Step 12 Fit new impeller to motor shaft. See figure 10a & 10b (ensure grub screw lines up with the flat on the shaft) Fit the screw to the impeller and wind down until you feel it touch the motor shaft.

  • Page 40: Appendix 6: Temperature Sensor Replacement

    APPENDIX 6: Temperature Sensor replacement Mealstream ovens manufactured before March 2004 If you are required to fit a new temperature sensor to a Mealstream 501 oven on a service call, you need to follow the procedure below to verify that the sensor is holding firm in the pocket. The diagram below shows the area of the thermistor causing the problem.

  • Page 41: Appendix 7: Fuse Change Flm020 Type

    APPENDIX 7: Fuse change (FLM20) 1 Mealstream ovens manufactured before March 2004 Brief description: 13A anti-surge fuses Pt. No. 30Z0168 are no longer manufactured these are now replaced with FLM020 fuses Pt. No. 30Z1177 for the Microwave circuit on all Mealstream 501 ovens. To replace a fuse on an oven manufactured before March 2004 and fitted with this fuse type it is necessary to replace the fuses and fuse holders with FLM 020 type.
  • Page 42 If fuse still blows, check microswitch setup is correct and replace if necessary. 9. Turn off the power and isolate the oven from the mains power supply. 10. Replace covers. 20A FUSE FLM SERIES MERRYCHEF PART No. 30Z1177 Page 42...
  • Page 43 APPENDIX 8: Tim Hortons Ovens 1 This appendix list the parts and procedures for Tim Hortons Mealstream 501 models which are a vend type oven pre-programmed from a MenuKey. In order to carry out the Power Test on Tim Hortons variant Ovens, the Icon Pad programs on the control panel need to be switched to Engineering Program Mode.
  • Page 44 APPENDIX 8: Tim Hortons Ovens 2 PROCEDURE FOR POWER OUTPUT MEASUREMENT The power output specification, 1425W on this model is established under IEC 705 standard method. This method is only workable in Laboratory controlled conditions. An approximate method is as follows: To carry out this test the Icon Pads need to be switched to ENGINEERING MODE PROGRAMS See previous page Fill one beaker ( glass or plastic ) with one litre ( 1.78 pints ) of tap water...
  • Page 45 APPENDIX 8: Tim Hortons Ovens 3 Door and cavity roof: Description Part No. Stirrer glass assy. ( inc. long seals ) 11C0319 Cavity roof seal (short) 790052 Door Handle Towel Rail 32Z1064 Bolt 1/4" 20 UNC 3/4" Hex 109050 Door Handle 40C1020 Spring Washer 31Z5005...
  • Page 46 APPENDIX 8: Tim Hortons Ovens 4 Tim Horton special parts: Tim Hortons Description Part No. Wire Rack 40C1011 Crumb Tray RBR290X02 Shelf Support 10C0174 Tim Hortons Shelf support fixing bolt 80T7133 Push fit bumper ( Rear Panel ) 31Z1187 Page 46...
  • Page 47 APPENDIX 8: Tim Hortons Ovens 5 Tim Hortons control panel MENU K Preheat L Cancel M Icon Cook Pads N MenuKey™ O Quarter, Half & Full Batch Load For 240V model Description Part No. Control Panel Assy with Menukey 11C0414 Logic Board 11C0411 Relay Board...

  • Page 48: Appendix 9: Door Interlock Set-Up Procedure

    APPENDIX 9: PROCEDURE DOOR INTERLOCK ADJUSTMENT TEST (1) The door on the Mealstream oven is monitored by three microswitches. These are used in the conventional “Primary, Secondary and Monitor” switch arrangement shown below. The switches operate as follows: Door Interlock Arrangement Switches shown in Door Closed position Secondary switch Primary switch...

  • Page 49: Procedure For Door Interlock Adjustment

    PROCEDURE DOOR INTERLOCK ADJUSTMENT TEST (2) Please Note DO NOT attempt to carry out the following procedure unless you have the following tools and parts. Continuity Meter Spacer No. required Part No. Door Spacer Kit 40C1119 S10 Door Spacer 10mm Part No.
  • Page 50 PROCEDURE DOOR INTERLOCK ADJUSTMENT TEST (3) Step 2: Insert S10 10mm spacer into door. Interlock Order (See figure 1 below for inserting spacer SW1 (Monitor) CLOSED correctly). SW2 (Primary) OPEN SW3 (Secondary) OPEN Step 3: Remove S10 10mm spacer and insert S1 1mm Interlock Order spacer into the door and close the door.

  • Page 51: Appendix 8: Tim Hortons

    Check for radiation leakage after servicing. Should the leakage 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 this requirement must be strictly observed. In addition, the leakage reading must be recorded on the service repair documentation while in the customer’s premises.
  • Page 52 • Readings must be below 4mW/cm². If a level greater that 4mW/cm² is observed, this should be reported to Merrychef Service Department immediately. • In any case, notes should be kept of the leakage that is observed. In terms of level and position on the oven.

  • Page 53: Manual Corrections And Modifications

    Name Address Page on which error occurs (if applicable) - Mealstream 500 Series Description of error Suggestion for improvement to manual Please return this form to: Service Dept.

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