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Merrychef
Mealstream 400
SERIES
S E R V I C E
M A N U A L
Part No. 32Z3311 Issue No. 9
For all Mealstream 401 and 403 models for GB & Europe manufactured from January 2001
CAUTION MICROWAVE EMISSIONS
DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE
GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY
Mealstream 401Ovens 32Z3311 Issue 9
Page 1
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Table of Contents
Related Manuals for Merrychef Mealstream 400 Series
Summary of Contents for Merrychef Mealstream 400 Series
- Page 1 Merrychef Mealstream 400 SERIES S E R V I C E M A N U A L Part No. 32Z3311 Issue No. 9 For all Mealstream 401 and 403 models for GB & Europe manufactured from January 2001 CAUTION MICROWAVE EMISSIONS...
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Page 2: Table Of Contents
Complete Spare Part Listing.......... 30-31 Circuit Diagrams ............32-38 Appendix 1 MenuKey Download Procedure......39 Appendix 2 Cleaning Procedure..........40 Appendix 3 Transformer Replacement........44 Manual corrections and modifications .........45 Merrychef and MenuKey™ are registered Trademarks of Merrychef Ltd. Mealstream 401Ovens 32Z3311 Issue 9 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 400 range of Combination Microwave Ovens. -
Page 4: Product Specifications
Product specifications: Mealstream 401 & 403 models ELECTRONIC CONTROLS: ( EC401 & EC403 models ) Model N : RMC1003 + Voltage + Frequency + Current + Controls + Phase + MenuKey + Catalytic converter For example: RMC100345XE52MK 230-240V, 50Hz, 30A, Series 5 Controls, Twin Phase, MenuKey Model Voltage Frequency... -
Page 5: Principles Of Operation
Principles of operation Mealstream 401Ovens 32Z3311 Issue 9 Page 5... -
Page 6: Installation Instructions
Installation instructions Positioning the Oven In order to maintain adequate ventilation for air intake and exhaust, and to allow access for cleaning the air filters, you must allow a minimum of 50mm clearance at the sides and rear of the oven, and at least 150mm above. Air intake temperature should not exceed 35°C. Excessive temperature will lead to reduced operating duty cycle or premature ageing of internal components. -
Page 7: Electrical Installation
Electrical installation: WARNING: This appliance must be earthed. Failure to do so may result in electric shock and death All models ( 30A ) must be connected to a separate electrical supply rated at WARNING 30 Amps by a qualified and approved electrician. A suitable 30 amp rated isolating switch with a 3mm contact gap on both poles should be fitted for each oven installed. -
Page 8: Error Codes And Diagnostics
Error codes and diagnostics The control panel will 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 9: Main Features
Main features rear view of Oven a STEAM OUTLET h TURNTABLE TRAY Allows steam and excess pressure to escape The vitreous enamelled turntable tray fits onto the from the oven cavity. It must be kept clear. turntable disc in the bottom of the oven cavity, and rotates during cooking to ensure an even b AIR OUTLET distribution of microwave energy. -
Page 10: Electronic Controls
Electronic controls: Mealstream EC401, EC403 Stage LED's Service Indicator Air Filter Block Indicator Operator error indicator Program Display Temperature Set Pads Time / Program Number Pads Cancel/ Callback Pad Program Pad Convection Pad Microwave power Pads On/Off switch m MenuKey socket 100% Starbucks model Mealstream 401Ovens 32Z3311 Issue 9... -
Page 11: Manual Controls
Manual controls: Mealstream RD401 Temperature Amber Neon Temperature Control Microwave Power Control Timer Start Pushbutton Cook cycle Red Neon Power Amber Neon On/Off switch Mealstream 401Ovens 32Z3311 Issue 9 Page 11... -
Page 12: Power Output Testing To En 60335-2-90
Procedure A - Power Output Test In accordance with BS EN 60335-2-90 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 13: Power Output Testing
Procedure B - Simplified Power Output Test You will need: A thermometer capable of reading to ±0.1°C. A Polypropylene tray approximately 200 mm x 200 mm. 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 14: 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 15: Door Interlock Operation
Door interlock operation The door on the oven is monitored by four microswitches. Three of these are used in the conventional “Primary, Secondary and Monitor” switch arrangement shown below, while the fourth is a low-voltage switch linked directly to the control circuitry. The switches operate as follows: Top RH Door Interlock Arrangement... -
Page 16: Casework
Principal components: casework 105A Handle Hanger RCK6319 Side Panel (L/H) MC3134 Rubber Foot RMC6104 Ferrite RMC6773 Upper Trim MC3120X01 Front Lower Panel MC3047 Top Plate RMC6759E Lower Trim MC3122 Exhaust Gallery RMC73372 PCB Retainer LH 40H0083 Rear Panel MC3129 PCB Retainer RH 40H0084 Air Filter MC3155... -
Page 17: Door Mechanism
Door mechanism Door Stay (R/H) MC3040 Hinge Body MC30121X02 Hook (A) RMC66171 Hook (B) RMC66172 Door Spring (B) MC3068X01 Hinge Body (L/H) MC30122X01 Door Spring (A) MC3067 Door Stay (L/H) MC3046 Microswitch Guide 40H0076 Solid Door Assy Black 11H0071 Solid Door Assy Silver MC3230X02 Mealstream 401Ovens 32Z3311 Issue 9 Page 17... -
Page 18: Oven Cavity Components & Hot Air System
Oven cavity components and hot air system 401 models 403 models 136A Turntable Disc RMC7340X01 Motor Bracket RMC7307X01 Baffle Plate Bolt CP30326 Cushion Rubber RCK8273 Baffle Plate MC3018 Motor Fixing Screw CP30310 Fan Fixing Cap RCK7617 Hot Air Motor MC3110 MC3111 Partition Plate 11H0007... -
Page 19: Oven Door Assembly
Oven door assembly Solid door assembly, Silver MC3230X02 Solid door assembly, Black 11H0071 Solid Door Assy. 11H0031 Silver Solid Door Assy Black 11H0071 Door Handle Silver RBR1285048 Door Frame (A) Black MC30503 Door Cover Outer 40H0080 Silver Door Cover Outer 40H0082 Black Inner Panel... -
Page 20: Magnetron & Door Interlock Components
Magnetron and door interlock components Model RMC1003__EE5 Model RMC1003__XE5 *If replacing a Sanyo Magnetron with a Panasonic Magnetron the HV capacitors need to be changed: XE & EE models 1.1 to 1.0µF (30Z1241) Inlet Duct RMC7193X01 54 Door Switch Bracket 40H0023 *Magnetron 30Z1171... -
Page 21: Magnetron & Door Interlock Components
Magnetron and door interlock components Model RMC1003__XX5 Model RMC1003__XX52 If replacing a Sanyo Magnetron with a Panasonic Magnetron the HV capacitors need to be changed: XX5 models 0.88 to 0.75µF (30Z1250) Magnetron Cut-out 30Z0088 54 Door Switch Bracket 40H0023 55 Primary Microswitch 30Z0240 Switch Bracket RMC7101X01... -
Page 22: Major Electrical Components
Major electrical components See Pages 23-25 Magnetron Overheat Switch 30Z0088 Temperature Sensor 50E123 Cavity Overheat Switch 30Z1031 HV Diode Assembly 11H0010 Bridge Rectifier (__EE only) 341520 117 Axial Fan, 80mm 310010 No. 8 Screw 31Z3107 M5 Screw 101825 Heating Element 220V 40H0077 Heating Element 240V 40H0009... -
Page 23: Input Wiring, Filters And Fuses
Input wiring, filters and fuses Model RMC1003__XE5, XD Model RMC1003__EE5, CD2 Green / Yellow Green / Yellow Blue Blue Brown Brown 112a Mains Input Block 31Z0328 Cable Gland 31Z1070 112A Cable Gland Nut 31Z1082 Input Cable Assembly 31Z0220 XE5 Input Cable Assembly 302030 Strain Relief Grommet 31Z1036... -
Page 24: Input Wiring, Filters And Fuses
Input wiring details: Model RMC1003__XX5, XX52 Green / Yellow Green / Yellow Blue Blue Brown 112a Mains Input Block 31Z0328 Cable Gland 31Z1070 112A Cable Gland Nut 31Z1082 Input Cable Assembly 31Z0220 XX5 Input Cable Assembly Strain Relief Grommet 31Z1036 77 Microwave Mains Filter 16A 30Z0997 78 Heater Mains Filter 16A... -
Page 25: Ht Components
HT Components: RMC1003__EE5/ XE5 HV Diode Assembly 11H0010 HT Transformer Top Bracket MC3127 HV Lead Assembly, Ferrite 11H0025 Oven Type Capacitor Value *Transformer 208-240V 50Hz 30Z1233 Part No. *Transformer 208-240V 60Hz 30Z1230 50Hz EE, XE, 30Z1331 x1 1.0uF 2500V CD2, XD2 HT Transformer Bottom 40H0070 Bracket... -
Page 26: Ht & Principal Components: Rmc1003
HT & principle components: Models RMC1003__XX5, RMC1003__XX52 Right side 76A Capacitor Clip 30Z1237 *Transformer 208-240V 50Hz 30Z1233 *Transformer 208-240V 60Hz 30Z1230 102 Resistor 470R 50W (Gold) 30Z0283 128 Cooling Fan 230V 50Hz 30Z1128 128 Cooling Fan 230V 60Hz 30Z1190 130 Diode Board 11H0058 132 Heater Relay 30Z0986... -
Page 27: Electronic Control Panel Assembly
Electronic control panel assembly 100% Membrane Panel Membrane Panel Menukey Starbucks (Blue) (Red/ Grey) Model Membrane Assy Logic PCB EE5, XE5, XX5 11H0060 11C0285 XX5 Starbucks 11H0024 11C0285 EE5, XE5, XX5 11H0067 11C0066 Menukey XX5 Locare 11H0073 11C0066 95 Membrane Assy See Table 103 Relay Assy. -
Page 28: Manual Controls Panel Assembly
Manual control panel assembly 124A 124B 124C 124D 105A PCB Retainer LH 40H0083 On/Off Switch 30Z0503 PCB Retainer RH 40H0084 105A Side Trim RH MC31212 M5 Flat Washer 31Z5004 PCB Assembly 11H0027 Timer 30Z0991 Amber Neon 316031 124A Control Knob Black 313020 124B Control Knob Skirt Red 313160... -
Page 29: 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 30: Complete Spare Part Listing
Part number identification chart 1 SIDE PANEL (L/H) MC3134 INSULATION PANEL 40H0081 FERRITE RMC6773 DOOR REINFORCEMENT RMC70722 UPPER TRIM MC3120X01 DOOR FRAME (B) MC3055 TOP PLATE RMC6759E INSULATION WRAP 32Z0001 EXHAUST GALLERY RMC73372 DOOR BASE SILVER MC3031KX04 REAR PANEL MC3129 DOOR COVER MC3064 GREASE FILTER... - Page 31 Part number identification chart 2 80MM AXIAL FAN 310010 M’WAVE MAINS FILTER 16A 30Z0997 PCB ASSEMBLY 11H0027 MAINS FILTER 16A TIMER 30Z0991 FUSE COVER 20Z1080 NEON AMBER 316031 FUSE 10A HRC 30Z0217 124A CONTROL KNOB BLACK 313020 FUSE HOLDER 1 INCH 30Z0231 124B CONTROL KNOB SKIRT RED...
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Page 32: Circuit Diagrams
Circuit diagram: RMC 1003__XE (30A) 40H0233 Issue 9 Date: 05.2007 Mealstream 401Ovens 32Z3311 Issue 9 Page 32... - Page 33 Circuit diagram: RMC 1003__5 EE & RMC 1003__XE 40H0072 Issue 6 Date: 08.2004 Mealstream 401Ovens 32Z3311 Issue 9 Page 33...
- Page 34 Circuit diagram: RMC 1003__5 EE & RMC 1003__XE (30A) 40H0233 Issue 9 Date: 05.2007 Mealstream 401Ovens 32Z3311 Issue 9 Page 34...
- Page 35 Circuit diagram: RMC 1003__XX5 (30A) 40H0234 Issue 3 Date: 05.2007 Mealstream 401Ovens 32Z3311 Issue 9 Page 35...
- Page 36 Circuit diagram: RMC 1003__XX5 (Single Phase) 40H0169 Issue 3 Date: 08.2004 Mealstream 401Ovens 32Z3311 Issue 9 Page 36...
- Page 37 Circuit diagram: RMC 1003__CD2 40H0090 Issue 3 Date: 08.2004 Mealstream 401Ovens 32Z3311 Issue 9 Page 37...
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Page 38: Circuit Diagrams
Circuit diagram: RMC 1003__CD2 40H0090 Issue 4 Date: 05.2007 Mealstream 401Ovens 32Z3311 Issue 9 Page 38... - Page 39 Circuit diagram: RMC 1003__5 EE & RMC 1003__XE ( Before August 2004 ) Mealstream 401Ovens 32Z3311 Issue 9 Page 39...
- Page 40 Circuit diagram: RMC 1003__XX5 (Single Phase) ( Before August 2004 ) Mealstream 401Ovens 32Z3311 Issue 9 Page 40...
- Page 41 Circuit diagram: RMC 1003__XX52 (Twin Phase) ( Before August 2004 ) Mealstream 401Ovens 32Z3311 Issue 9 Page 41...
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Page 42: 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 43: Appendix 2 Cleaning Procedure
As with all electrical appliances, it is wise to have the electrical connections inspected periodically. Merrychef recommends the use of approved Merrychef Oven Cleaner and Merrychef Oven Cleaning the air filter oven cavity, and door Protector. -
Page 44: Appendix 3 Transformer Replacement
APPENDIX 3 : Transformer Replacement Procedure Should you need to change a transformer to any Mealstream 401 EE or XE product, you should use the new 30Z1233 or 30Z1230 (multi-tap) transformers. (see matrix below) Note: The capacitor values remain the same when using the new 30Z1233 or 30Z1230 transformer. Parts required: Pt. -
Page 45: Manual Corrections And Modifications
Name Address Page on which error occurs (if applicable) - Mealstream 400 Series Description of error Suggestion for improvement to manual Please return this form to: Service Dept.
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