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

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Merrychef
Version 3.0
Version 2.0
402s
S E R V I C E & P A R T S M A N U A L
This manual covers UK/EC models manufactured from:
ISSUE 5
Version 2.0 Serial No. 000745 –001199
23.09.2008
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
o.
402s Ovens Part. N
32Z3539 Issue 5
1

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Summary of Contents for Merrychef 402s

  • Page 1 ISSUE 5 Version 2.0 Serial No. 000745 –001199 23.09.2008 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 Part. N 32Z3539 Issue 5...

  • Page 2: Table Of Contents

    Appendix 7: Electrical Installation Guide .......55 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 402s Ovens Part. N 32Z3539 Issue 5...

  • Page 3: 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 4: Product Specifications

    Month 00/ Year 00/ Production number 00000 e.g 01 08 03349 Oven manufactured January, 2008, production number 03349 Model Number: 402S VVV F P C R TT ZZ Example 402S2205BK2GMEU Model No. EC402s 220V, 50Hz, L1 +L2 +N +Earth supply, MenuKey Revision 1, General Market, EU Supply Freq.

  • Page 5: Installation Instructions

    Installation Instructions for Mealstream 402s Ovens Power Supply Requirements The Mealstream 402s should be connected to a suitable electricity supply, which can cope with the switching-on surge that occurs with certain types of catering equipment, including microwaves. Because of this requirement, we strongly recommend that a separate, suitably rated supply is installed for the oven.

  • Page 6: 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 Part. N 32Z3539 Issue 5...

  • Page 7: Main Features Control Panel Version 2.0

    Indicates combustion ( fire ) in oven cavity than 50°C above PREHEAT Note: In service operations when temperature setting during cook cycle PREHEAT is set to 0°C this message can appear when the oven is operated 402s Ovens Part. N 32Z3539 Issue 5...

  • Page 8: Main Features Control Panel Version 3.0

    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°C in 10 minutes and need to be replaced 402s Ovens Part. N 32Z3539 Issue 5...

  • Page 9: Principal Components: Rhs

    30Z1295 HV Capacitor 2500V 1.1µF ( 50HZ models ) 30Z1242 HV Capacitor 2500V 0.88µF ( 60HZ models ) 30Z1251 26A HV Capacitor universal clip 31Z1261 Fibre Optic PCB 11M0364 Solid State Relay 30Z1362 402s Ovens Part. N 32Z3539 Issue 5...

  • Page 10: Principal Components: Lhs

    Motor Controller 30Z1319 Thermistor Cavity 30Z1315 HV Capacitor 2500V 1.0µF ( 50Hz models ) 30Z1331 HV Capacitor 2500V 0.88µF ( 60Hz models ) 30Z1251 25A HV Capacitor clip 31Z1261 Fibre Optic PCB 11M0364 402s Ovens Part. N 32Z3539 Issue 5...

  • Page 11: Principal Components: Control Box

    11Z0298 Ribbon Cable 10way MenuKey 11M0117 Logic PCB Assembly Version 2.0 11K0002 Logic PCB Assembly Version 3.0 11K0012 Transformer LT (Low voltage) 30Z1155 Fuse 1A 30Z0957 Sounder SA257 Fibre Optic Logic PCB 11K0013 402s Ovens Part. N 32Z3539 Issue 5...

  • Page 12: Principal Components: Back View

    Convection ( Hot Air ) Motor Assembly SA208 30Z1233 Transformer 208/220/240V 50Hz Transformer 208/220/240V 60Hz 30Z1230 HT Diode Assy PCB (Fibre Optic) 11H0364 HT Diode Assembly ( Non-optic) 11H0010 Magnetron Cooling Duct LH DV0039 Magnetron Cooling Duct RH DV0040 402s Ovens Part. N 32Z3539 Issue 5...

  • Page 13: Principal Components: Power Supply

    Cable Gland Nut 31Z0499 Electrical Supply Lead Assembly Single Phase SA226 Electrical Supply Lead Assembly Twin Phase SA225 Terminal Block 31Z0447 Fuse 20A FLM 30Z1177 Fuse Holder 30A 30Z1178 Fuse Holder 10A 30Z0231 402s Ovens Part. N 32Z3539 Issue 5...

  • Page 14: Principal Components: Cavity Parts & Kfc Accessories

    * Parts 35 & 37 Contact Service Department KFC Accessories 65 Chicken Griddle SA133 Description Part No. Cool-down pan 32Z4028 Oven tray MC3175 Handle Assembly SA267 Griddle DV0221 Griddle carrier SA350 Chicken Griddle (SA350 + DV0221 + DV0267) SA133 402s Ovens Part. N 32Z3539 Issue 5...

  • Page 15: Principal Components: External Panels & Parts

    Door Skin DV0501 Door Handle 32Z1066 Door Inner SA331 Door Choke DV0168 Door Seal (wide) DV0305 Door seal sealant ( tube ) 31Z0186 Bottom Trim DV0037 Side Panel RH DV0092 Door Assembly SA111 402s Ovens Part. N 32Z3539 Issue 5...

  • Page 16: Principal Components: Electronic Control Panel Assembly

    DV0055 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 Part. N 32Z3539 Issue 5...

  • Page 17: Parts Matrix

    HV Capacitor clip universal 30Z1233 Transformer 208/220/240V 50Hz 30Z1230 Transformer 208/220/240V 60Hz 11H0010 HT Diode Assy SA226 Electrical Supply Lead Assembly SA225 Electrical Supply Lead Assembly Twin Phase 31Z0447 Terminal Block 30Z1177 Fuse 20A FLM 402s Ovens Part. N 32Z3539 Issue 5...
  • Page 18 Power switch (On/Off) 30Z1318 — Microswitch interlock Spring 31Z1247 Membrane GM Version DV0055 Version 2.0 Front Panel Version 2.0 DV0036 Display Assembly 30Z1299 & Header Version 2.0 MenuKey Socket 11K0005 SA257 Sounder 32Z4028 Cool-down pan 402s Ovens Part. N 32Z3539 Issue 5...

  • Page 19: Procedure For Power Output Measurement

    15ºC ( 27ºF ) Minimum 20ºC ( 36ºF ) 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 Part. N 32Z3539 Issue 5...

  • Page 20: 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 Part. N 32Z3539 Issue 5...

  • Page 21: High Voltage Rectifier Test

    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 Part. N 32Z3539 Issue 5...

  • Page 22: 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 23: Procedure For Door Interlock Adjustment And Test

    CLOSED and then allow the assembly to move 1-2mm to just allow the switch to return to the OPEN position and tighten all 4 screws. CLOSED Repeat the procedure on the RHS of the 402s Ovens Part. N 32Z3539 Issue 5...
  • Page 24 If the meter reads Open Circuit, remove the 2mm spacers and repeat steps 1-4 moving the switch assemblies very slightly further down. This procedure may need to be repeated several times to achieve a satisfactory arrangement. 402s Ovens Part. N 32Z3539 Issue 5...

  • Page 25: Hot Air Motor And Controller

    Motor winding resistances: Blue-Black 3 Ohms—4 Ohms Black-Brown 3 Ohms—4 Ohms Brown-Blue 3 Ohms—4 Ohms Black or Brown or Blue to Earth (Open circuit) SA208 Hot Air Motor Assembly 8x 31Z4016 M5 Flange nut 402s Ovens Part. N 32Z3539 Issue 5...
  • Page 26 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 Part. N 32Z3539 Issue 5...

  • Page 27: Circuit Diagram

    402s Ovens Part. N 32Z3539 Issue 5...
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  • Page 35: Troubleshooting Guide

    • 1.0 No Display • 3.0 Cavity Sensor Error • 4.0 Magnetron / Over heat errors Note : The following Diagnosis procedures may not expose all possible errors but have been included for general guidance. 402s Ovens Part. N 32Z3539 Issue 5...
  • Page 36 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 Part. N 32Z3539 Issue 5...
  • Page 37 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 Part. N 32Z3539 Issue 5...
  • Page 38 1. The cavity did not heat by 100°C in the 10 Minutes Replace Sensor Re-test and calibrate 2. The cavity Exceed the set point when cooking by more than 40°C whilst cooking which indicates that the food load was on fire 402s Ovens Part. N 32Z3539 Issue 5...
  • Page 39 High Voltage in Temperature the magnetron area. reading > 60°C 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 Part. N 32Z3539 Issue 5...

  • Page 40: Appendix 1: Temperature Sensor Resistance Data

    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 Part. N 32Z3539 Issue 5...

  • Page 41: Appendix 2: Menukey Download Procedure V2.0

    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 32Z3539 Issue 5...

  • Page 42: Menukey Download Procedure V3.0

    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 32Z3539 Issue 5...

  • Page 43: Appendix 3: Cool Down & Cleaning Procedure

    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 Part. N 32Z3539 Issue 5...
  • Page 44 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 45 Oven Protector onto the surfaces of the oven surface of the oven door reached operating sponge temperature it will take 30 minutes to cure the Oven Protector. Note: oven protector turns light brown when cured 402s Ovens Part. N 32Z3539 Issue 5...

  • Page 46: Appendix 4: Recommended Spares List

    LOGIC BOARD MAIN ASSY V2.0/2.5 SA288 STIRRER MOTOR ASSY SA260 LOGIC BOARD MAIN ASSY V3.0 SA276 AIR FILTER SA314 CATALYST ASSY UPPER SA315 CATALYST ASSY LOWER SA329 REAR PANEL SA339 GREASE FILTER HOUSING SA340 GREASE FILTER CARTRIDGE 402s Ovens Part. N 32Z3539 Issue 5...

  • Page 47: Appendix 5: Pcb Connection Points

    New PCB if Guide Membrane panel PCB replaced. connector Fibre Optic Fibre Optic Fibre Optic Magnetron Detector 2 to RHS Detector 1 to LHS Detection Solid State Relay Heater regulation Magnetron 1 circuit Magnetron 2 402s Ovens Part. N 32Z3539 Issue 5...
  • Page 48 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 Part. N 32Z3539 Issue 5...

  • Page 49: Appendix 6: Firmware Revision Guide

    APPENDIX 6: 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 50 MenuKey Code: MenuKey Checksum F076 PAUSE>> Check the Software Version on the Oven Start Up screen and refer to Table 1 below Firmware Verification: Table 1 Firmware Version for 402s V3 ovens 2.8LD 3.0LD 4.0LD 4.1LD 4.2LD 4.3LD 4.4LD Abbreviation...
  • Page 51 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 Part. N 32Z3539 Issue 5...
  • Page 52 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 Part. N 32Z3539 Issue 5...
  • Page 53 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 Part. N 32Z3539 Issue 5...
  • Page 54 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 Part. N 32Z3539 Issue 5...

  • Page 55: Appendix 7: Electrical Installation Guide

    APPENDIX 7: Electrical Installation Guide 402s Ovens Part. N 32Z3539 Issue 5...

  • Page 56: Manual Corrections And Modifications

    Please return this form to: Service Dept. 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: technical.support@merrychef.com 402s Ovens Part. N 32Z3539 Issue 5...

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