Page 1
Mealstream
SERVICE
ALL CTM3 MODELS & TIM HORTON'S COMBINATION OVEN
MANUFACTURED FROM JANUARY 2003
CAUTION MICROWAVE EMISSIONS
DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE GENER ATOR
OR PARTS CONDUCTING MICROWAVE ENERGY
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 1
SERVICE MANUAL
Page 2
TABLE OF CONTENTS
Microwave safety precautions ................................................. 3
Safety code ............................................................................. 4
Product specifications ............................................................. 5
Installation instructions............................................................ 6
Main features ....................................................................... 7-8
Principal components: LHS ..................................................... 9
Principal components: RHS .................................................. 10
Principal components: Top.................................................... 11
Principal components: Back view.......................................... 12
Principal components: door, roof and heater element ..........13
Principal components: Cavity Parts & External Panels ......... 14
Principal components: Electronic control panel assembly .... 15
Principal components: Tim Hortons Control panels .............. 16
Principal components: ( not shown in main views ) ............. 17
Principal components: Input wiring details ............................ 18
Principal components: Part no. identification charts ........ 19-21
Procedure for Microwave leakage test ............................. 22-23
Procedure for Power output measurement ........................... 24
Procedures for Principal Component tests ......................25-26
Procedure for Door interlock adjustment and test .......... 27-29
Procedure for building and fitting the door ....................... 30-34
Procedure for replacing door seal assembly.................... 35-36
Procedure for removing shelf runners & element cover ........ 37
Procedure for replacing Heater Element...............................38
Procedure for replacing Hot air Motor assembly................... 39
Procedure for replacing Magnetron assembly .................40-41
Procedure for Testing Membrane panel circuit ................ 42-43
Circuit diagrams ..............................................................44-47
Error codes and diagnostics.................................................. 48
Appendix 1: Test Procedure for Tim Hortons........................ 49
Appendix 2: MenuKey® Download procedure ...................... 50
Appendix 3: Temperature Sensor resistance data ................ 51
Manual corrections and modifications................................... 52
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 2
Page 3
MICROWAVE SAFETY
CAUTION
WARNING TO SERVICE TECHNICIANS
PRECAUTIONS TO BE OBSERVED BEFORE AND DURING
SERVICING TO AVOID POSSIBLE EXPOSURE TO
EXCESSIVE MICROWAVE ENERGY
(a) Do not operate or allow the oven to be operated with the door open.
(b) Make the following safety checks on all ovens to be serviced before
activating the magnetron or other microwave source , and make repairs
as necessary:
1) interlock operation.
2) proper door closing.
3) seal and sealing surfaces (arcing, wear, and other damage).
4) damage to or loosening of hinges and latches.
5) evidence of dropping or abuse.
(c) Before turning on microwave power for any service test or inspection
within the microwave generating compartments, check the magnetron,
wave guide or transmission line, and cavity for proper alignment,
integrity and connections.
(d) Any defective or misadjusted components in the interlock, monitor, door
seal, and microwave generation and transmission systems shall be
repaired, replaced, or adjusted by procedures described in this manual
before the oven is released to the owner.
(e)(i) A microwave leakage check to verify compliance with the Federal
Performance Standard should be performed on each oven prior to
release to the owner. For U.S.A.
(e)(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. For CANADA.
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 3
Page 4
SAFETY CODE
This manual is designed to assist engineers who have been on a recognised product
familiarisation and training course run by Garland. It has been prepared to offer technical
guidance for the Mealstream range of Combination Microwave 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.
To avoid injury to yourself, and to protect the appliance from possible damage, please follow this
Safety Code when servicing these ovens.
Before attempting to repair the oven, check it for microwave leakage.
Check that the oven is not emitting microwaves, even when supposedly not in
operation.
Check that the oven is not operating continuously, whether the display indicates
cooking or not.
Always discharge the HT capacitors before working on the oven using a suitably
insulated 10 MΩ Resistor.
Before removing any covers from the oven, do all of the following.
• Switch off the mains supply and remove the plug from the wall socket.
or
• If the oven is hard wired, ensure that the power is turned off at the isolator switch.
Note:
The On/Off switch on the oven is not adequate protection against electric
shock, as it does not isolate all of the internal wiring from the mains.
Upon completion of a service on a Mealstream oven, or before reconnecting the appliance to the
electrical supply for testing, check all of the following points:
• All internal electrical connections are correct (see wiring diagram Page 44-47).
• All wiring insulation is correct and is not touching a sharp edge.
• All grounding connections are electrically and mechanically secure.
• All door safety interlocks are secure and mechanically sound.
• The door operation is smooth, and the arms run freely in the slots.
• The door activates all three of the door interlock switches in the correct order
(see pages 27-29).
• The temperature sensor is correctly connected to the Power PCB.
Before finishing a service call, recheck the following points:
• All of the electronics are functioning correctly, and all of the touch pads are working.
• Microwave emissions are below permissible limit - 4 mW/cm².
• The power output of the oven is checked in accordance with page 24.
• Oven has correct 2 inch ( 50mm ) air gap all round and 2 inch ( 50mm ) above.
Air flow should not be restricted. (see page 6).
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 4
Page 5
PRODUCT SPECIFICATIONS
Model Number: + Voltage + Frequency + Phases + Controls + Country
Model No. CTM3
Voltage
Frequency
Phases
Control Type
Country
Customer Variant
Power
Requirements
208Volts
240Volts
Power Output Microwave 100%
Convection
Combination
External
Dimensions
Height
Width
Depth
208V 20
240V 24
50Hz 50
60Hz 60
Single 1
Three 3
Series 5 S5
UK UK
N.America A
N.America TH = Tim Hortons
208V ac 60Hz 30Amp 2P & G
240V ac 60Hz 40Amp 2P & G
1425W
3000W
1425W + 3000W
30 inches ( 765mm )
29.5 inches ( 770mm )
25 inches ( 635 mm)
Manufacturers
recommended
clearances
Height
Width
Depth
Internal
Dimensions
Height
Width
Depth
Capacity
Weight Nett
Gross packed
Construction Cavity
Casework
Settings Microwave
Temperature
Timer
Programs
Mealstream Ovens Pt. No. 32Z3403 Issue 15
32 inches ( 815 mm )
31.5 inches ( 795 mm )
27 inches ( 685 mm)
10.2 inches ( 260mm )
19.3 inches ( 490mm )
14.2 inches ( 360mm )
1.62 ft³ ( 45.86 litres )
198 lb.s ( 90 kg )
227 lbs ( 103 kg )
304 Stainless Steel
100%,75%,50%,25%, Convection only
Off, 300°F, 350°F, 400°F, 440°F, 480°F
Up to 30 minutes per stage
Cook Programs can have 3 cooking stages of up to 30
minutes for each stage
Page 5
Page 6
INSTALLATION INSTRUCTIONS
Installation Instructions for Mealstream Combination Ovens
Power Supply Requirements
The Mealstream Series 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.
The supply for the oven should be fitted with a Type "C" or Time Delay circuit breaker,
rated at:
50 Amp for 208V electrical supply ( 2PH + GND )
50 Amp for 240V electrical supply ( 2PH + GND )
30 Amp for 208V electrical supply ( 2PH + GND )
30 Amp for 240V electrical supply ( 2PH + GND )
If the oven is hard-wired to the supply, a double-pole isolator switch with a contact gap of at
least 1/8 inch ( 3 mm ) should be fitted.
Grounding requirement
This appliance must be connected to a grounded, metallic, permanent wiring system, or an
equipment grounding conductor should be run with the circuit conductors and connected to the
equipment grounding terminal or lead on the appliance.
Canada models
US models
Positioning the Oven
In order to maintain adequate ventilation for air intake
and exhaust, and to allow access for cleaning filters,
you must allow a minimum of 2 inches ( 50 mm )
clearance at the sides and rear of the oven,
and at least 2 inches ( 50 mm ) above.
Air intake temperature should not exceed 110°F/45°C
excessive temperature will lead to reduced operating
duty cycle, or premature ageing of internal components.
Failure to comply with these conditions will invalidate
the warranty.
NEVER Install an oven above fryers,
grills, griddles or any other
major heat source.
NEVER Stack machines on top of
each other. Always use a
double stand or a separate
shelf.
ALWAYS Place containers in the cavity
carefully - impact damage
may chip the vitreous enamel
coating on the runners and
baffle plate.
Note:
The minimum recommended
clearance required for air flow
31.5ins
27ins
32ins
16ins
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 6
Page 7
MAIN FEATURES
a
b
c
d
e
k
a
On/Off SWITCH
This is used to turn the oven On or Off.
IT DOES NOT ISOLATE INTERNAL
WIRING FROM THE MAINS SUPPLY.
EXHAUST VENTS
b
Allows exhausted air from the magnetron
cooling system to escape.
f
HOT AIR FAN
Situated behind the baffle plate, and
circulates the hot air through the baffle
plate, over the heating element, and around
the edge of the baffle plate back into the
cavity.
g
RATING PLATE
b
f
g
j
i
h
OVEN CAVITY
c
The oven cavity is mainly constructed
from stainless steel panels. It must be
kept clean.
BAFFLE PLATE
d
Forms the inside rear of the oven and
covers the hot air circulation fan. This
must be cleaned on a regular basis, and
kept free of debris.
RUNNERS
e
These are mounted on each side of the
oven cavity to support the rectangular
racks or oven trays.
Mealstream Ovens Pt. No. 32Z3403 Issue 15
The rating plate is situated on the rear of
the oven, and states the Model, Serial
Number, Electrical Ratings and
Manufacturers telephone number.
h
DOOR
The door consists of a thermally insulated
inner section, and an additional air gap
provided by a twin skinned door front to
lower the surface temperature.
i
DOOR SEAL
ELECTRICAL SUPPLY CORD
j
Electrical supply cord is situated on the rear
of the oven,
AIR FILTER
k
Main intake for cooling air for internal
components. Must be clear of obstructions.
Page 7
Page 8
MAIN FEATURES
Electronic control panel
j
i
h e
Stage LED's
a
Program & Time Display
b
Convection Pad
e
Power Pads
f
Time / Preset Pads
g
Temperature Set Pads
h
Cancel / Callback Pad
i
a
b
f g
N
K
j
N
Tim Hortons control panel
Preheat
K
L
L
Cancel
Program Pad
Menukey™
M
a
M
b
O
N
MENU
KEY
Icon Cook Pads
M
MenuKey™
N
Quarter, Half & Full Batch Load
O
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 8
Page 9
PRINCIPAL COMPONENTS
Left side
1
1A
2
2A
3A
3
4
4A
14
5
5A
6
7
8
9
No Description 208V 240V
1 Fuse holder 30Z0231 30Z0231
1A Fuse 10 amp 30Z0217 30Z0217
2 Fuse holder 30Z0231 30Z0231
2A Fuse 10 amp 30Z0217 30Z0217
3 Fuse holder 30Z0285 30Z0285
3A Fuse 1 amp 30Z0957 30Z0957
4 Fuse holder 30Z1178 30Z1178
4A Fuse 20 amp 30Z1177 30Z1177
5 Fuse holder 30Z1178 30Z1178
5A Fuse 20 amp 30Z1177 30Z1177
6 Electrical supply terminal block 31Z0149 31Z0149
7 Filter ( Heater circuit ) 30Z0997 30Z0997
8 Filter ( Microwave circuit ) 30Z0997 30Z0997
9 Door spring (short type) 520000 520000
9 Door spring( Long )A 40C1141 40C1141
10 Door arm stop assembly 11C0279 11C0279
11 Microswitch ( Primary ) 30Z0240 30Z0240
12 Door hinge assembly ( LH )B 11C0167 11C0167
13 Door arm assembly 11C0300 11C0300
14 Microswitch ( Monitor ) 30Z0240 30Z0240
13
12
11
10
Note A
Ovens after
June 2003
Note B
See page 17
for parts
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 9
Page 10
PRINCIPAL COMPONENTS
Right side
95
22
59
15
16
17
19 18
No Description 208V 240V
15 Door arm assembly 11C0300 11C0300
16 Door hinge assembly ( RH )
B
11C0166 11C0166
17 Micro-switch ( Secondary ) 30Z0240 30Z0240
18 Door arm stop assembly 11C0279 11C0279
21
20
90
Note B
See page 17
for parts
19 Door spring 520000 520000
Door spring( Long )A 40C1141 40C1141
19
20 Steam pipe 40C1023 40C1023
21 Steam vent guard 790061 790061
22 Temperature sensor 50E123 50E123
59 Rubber stop 31Z1150 31Z1150
90 Cavity Vent Pipe 40C1013 40C1013
95 Diode Board assy. with leads 11M0325 11M0325
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 10
Note A
Ovens after
June 2003
Page 11
PRINCIPAL COMPONENTS
Top view
87
23
24
63
26
27
60
61
87
23
24
63
26
27
28
No Description 240V
23 Magnetron (Panasonic) 30Z1171
24 Resistor 470 R 30Z0283
26 Capacitor 0.88µf (2300V)A 30Z0861
26 Capacitor 0.88µf (2500V) Kit 10C0192
27 Transformer 30Z1191
28 Twin blower motor
60 25mm OD Flexible conduit
61 20mm OD Flexible conduit
62 Capacitor clip (99mm)
63 Filter 30Z0997
87 Magnetron Thermal Trip 2571016
Note A: This Capacitor is replaced with 0.88µf 2500V and 2 x 109mm clips
included in a service kit Part No. 10C0192
208V
30Z1171
30Z0283
30Z0861
10C0192
30Z1139
30Z1145
314402
314401
31Z0176
62
30Z1067
314402
314401
31Z0176
N/A
2571016
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 11
Page 12
PRINCIPAL COMPONENTS
Back view
94
88
64
65
104 105
No Description 208V 240V
64 Hot air motor assembly 11C0312
65 Capacitor 6µF 30Z1148
88 Overheat Safety Thermostat 30Z1024
94 Hot Air motor Resistor 50R N/A
104 Twin Blower Resistor 39R N/A
105 Twin Blower Resistor 50R N/A
11C0312
30Z1148
30Z1024
30Z1165
30Z1164
30Z1165
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 12
Page 13
PRINCIPAL COMPONENTS
Door and cavity roof
86
72
86
67
106
107
77
108
109
71
89
76
No Description 208V 240V
53 M5 Hex/hd s/s Screw 101825 101825
67
71 Door seal kit 11C0292 11C0292
72 Door choke 790007 790007
86 Cavity roof seal (short) 790052 790052
93
76 Door Handle Towel Rail 32Z1064 32Z1064
77 Bolt 1/4" 20 UNC 3/4" Hex 109050 109050
Stirrer glass assy. ( inc. long seals )
Door Assembly Garland 11C0336 11C0336
Door Assembly Tim Hortons 11C0380 11C0380
Door Assembly Unbranded 11C0418 11C0418
11C0319 11C0319
89 Door Handle 40C1020 40C1020
106 Flat Washer S/S M5 x 20 104036 104036
107 Nylon Washer 104250 104250
108 Spring Washer 31Z5005 31Z5005
109 Flat Washer S/S M6 x 20 104054 104054
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 13
Page 14
PRINCIPAL COMPONENTS
Heater Element and Cavity parts
57
68
102
70
85
No Description 208V 240V
57 Mesh washer 31Z5044 31Z5044
68 Heater element 40C0949 40C0948
69 Heater element cover plate 790047 790047
70 Baffle 11C0311 11C0311
85 Dome Nut 80X7025 80X7025
92 Tray Support 40C0950 40C0950
102 Hot Air Impeller MC3111 MC3111
103
Hot Air Impeller Securing Nut
70
69
103
105065 105065
92
92
External Parts and accessories
96
110
99
No Description 208V 240V
96 Side Panel Left Side 790002 790002
97 Side Panel Right Side 790003 790003
98 Top Panel 790005 790005
99 Foot 32Z1052 32Z1052
100 Wire Rack 40C1011 40C1011
101 Crumb Tray RBR290X02 RBR290X02
110 Rear Outer Panel 40C0951 40C0951
98
97
100
101
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 14
Page 15
PRINCIPAL COMPONENTS
Electronic Control Panel Assembly
29
34
33
32
31
73
30
Tim Hortons
See page 16
No Description 208V 240V
29 On/Off Switch 30Z0503 30Z0503
30 Control Panel Assy with Menukey
(except Tim Hortons)
31 Logic Board (except Tim Hortons) 11C0377 11C0377
32 Relay Board (except Tim Hortons) 11C0316 11C0212
33 AC Ribbon connector 11M0116 11M0116
34 DC Ribbon connector 11M0117 11M0117
73 MenuKey Assembly 10C0148 10C0148
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 15
11C0379 11C0379
Page 16
TIM HORTONS CONTROL PANEL
US/ English
No Description 208V 240V
30 Control Panel Assy with Menukey 11C0332 11C0332
31 Logic Board 11C0331 11C0331
32 Relay Board 11C0316 11C0212
US/ English 1/4 Load
No Description 208V 240V
30 Control Panel Assy with Menukey 11C0412 11C0412
31 Logic Board 11C0411 11C0411
32 Relay Board 11C0402 11C0403
French Canadian
No Description 208V 240V
30 Control Panel Assy with Menukey 11C0413 11C0413
31 Logic Board 11C0411 11C0411
32 Relay Board 11C0402 11C0403
Unbranded
No Description 208V 240V
30 Control Panel Assy with Menukey 11C0414 11C0414
31 Logic Board 11C0411 11C0411
32 Relay Board 11C0402 11C0403
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 16
Page 17
PRINCIPAL COMPONENTS
( not shown in main views )
Left Hand Door Hinge
12
54
53
Motor shaft screen and
seal assembly
Assembly
52
51
55
58
Right Hand Door Hinge
16
52
51
56
Stirrer motor assembly
Assembly
54
53
49
50
No. Description All models
12 Door Hinge Assembly LH 11C0167
16 Door Hinge Assembly RH 11C0166
49 Motor shaft screen 40C1005
50 Hot air motor damper/seal 40C1008
51 Pin 790027
52 Roller 40C0752
53 M5 Hex/hd s/s Screw 101825
54 M5 stainless steel Nut 80X7003
55 LH Hinge bracket 790024
56 RH Hinge bracket 790025
58 Stirrer motor assembly 11C0162
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 17
Page 18
PRINCIPAL COMPONENTS
Input wiring details
Green/Yellow
6
L1 L2
48 46
No Description All models
Green
Black
White
47
6 Electrical Supply Terminal Block 31Z0149
46 Cable Gland 31Z0500
47 Gland Nut 31Z0499
48 Electrical Supply Cord 3 Core 30Z1162
91 Electrical Supply Plug 50Amp
(Canada)
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 18
31Z0298
Page 19
PRINCIPAL COMPONENTS: Part Number Identification Chart 1
No
1
1A Fuse 10 amp 30Z0217 30Z0217 9
2 Fuse holder 30Z0231 30Z0231 9
2A Fuse 10 amp 30Z0217 30Z0217 9
3 Fuse holder 30Z0285 30Z0285 9
3A Fuse 1 amp 30Z0957 30Z0957 9
4 Fuse holder 30Z1178 30Z1178 9
4A Fuse 20 amp 30Z1177 30Z1177 9
5 Fuse holder 30Z1178 30Z1178 9
5A Fuse 20 amp 30Z1177 30Z1177 9
6 Electrical supply terminal block 31Z0149 31Z0149 9/18
7 Filter ( Heater circuit ) 30Z0997 30Z0997 9
8 Filter ( Microwave circuit ) 30Z0997 30Z0997 9
9
10 Door arm stop assembly 11C0279 11C0279 9
11 Microswitch ( Primary ) 30Z0240 30Z0240 9
12 Door hinge assembly ( LH ) 11C0167 11C0167 9/17
13 Door arm assembly 11C0300 11C0300 9
14 Microswitch ( Monitor ) 30Z0240 30Z0240 9
15 Door arm assembly 11C0300 11C0300 10
16 Door hinge assembly ( RH ) 11C0166 11C0166 10/17
17 Microswitch ( Secondary ) 30Z0240 30Z0240 10
18 Door arm stop assembly 11C0279 11C0279 10
19 Door spring 520000 520000 10
20 Steam pipe 40C1023 40C1023 10
21 Steam vent guard 790061 790061 10
22 Temperature sensor 50E123 50E123 10
23 Magnetron 30Z1171 30Z1171 11
24 Resistor 470 R 30Z0283 30Z0283 11
25 HT diode 11C0266 11C0266 11
26 Capacitor 0.88µf (2300V) 30Z0861 30Z0861 11
26 Capacitor 0.88µf (2500V) Kit 10C0192 10C0192 11
27 Transformer 30Z1139 30Z0992 11
28 Twin blower motor 30Z1145 30Z1067 11
29 On/Off Switch 30Z0503 30Z0503 15
30 Control Panel Assembly (Except Tim Hortons) 11C00379 11C0379 15
31 Logic Board (Except Tim Hortons) 11C0377 11C0377 15
Description
Fuse holder 30Z0231 30Z0231 9
Door spring 520000 520000 9
Door spring( Long ) 40C1141 40C1141 9
Door spring( Long )A 40C1141 40C1141 10
Control Panel Assembly US Tim Hortons 11C0412 11C0412 16
Control Panel Assy. French C. Tim Hortons 11C0413 11C0413 16
Control Panel Assy. UnBranded Tim
Hortons
Logic Board Tim Hortons 11C0411 11C0411 16
Part No
208V 240V
11C0414 11C0414 16
Page No
Note A
Ovens after
June 2003
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 19
Page 20
PRINCIPAL COMPONENTS: Part Number Identification Chart 2
No
46 Cable Gland 31Z0500 31Z0500 18
47 Gland Nut 31Z0499 31Z0499 18
48 Mains Cable 3 Core 30Z1162 30Z1162 18
49 Motor shaft screen 40C1005 40C1005 17
50 Hot air motor damper/seal 40C1008 40C1008 17
51 Pin 790027 790027 17
52 Roller 40C0752 40C0752 17
53 M5 Hex/hd s/s Screw 101825 101825 13/17
54 M5 stainless steel Nut 80X7003 80X7003 17
55 LH Hinge bracket 790024 790024 17
56 RH Hinge bracket 790025 790025 17
57 Mesh washer 31Z5044 31Z5044 14
58 Stirrer motor assembly 11C0162 11C0162 17
59 Rubber stop 31Z1150 31Z1150 10
60 25mm OD Flexible conduit 314402 314402 11
61 20mm OD Flexible conduit 314401 314401 11
62 Capacitor clip (99mm) 31Z0176 31Z0176 11
63 Filter 30Z0997 N/A 11
64 Hot air motor assembly 11C0312 11C0312 12
65 Capacitor (Motor starter) 30Z1148 30Z1148 12
67 Stirrer glass assy. 11C0319 11C0319 13
68 Heater element 40C0949 40C0948 14
69 Element cover plate 790047 790047 14
70 Baffle 11C0311 11C0311 14
71 Door seal kit 11C0292 11C0292 13
72 Door choke 790007 790007 13
73 Menu-Key Assembly 10C0148 10C0148 15
76 Handle 32Z1064 32Z1064 13
77 Bolt 1/4" 20 UNC 3/4" Hex 109050 109050 13
85 Dome Nut 80X7025 80X7025 13
86 Cavity roof seal (short) 790052 790052 13
87 Magnetron Thermal Trip 2571016 2571016 10
88 Cavity Overheat Thermostat 30Z1024 30Z1024 12
89 Door Handle 40C1020 40C1020 13
90 Cavity Vent Pipe 40C1013 40C1013 10
91 Electrical Supply Plug (50A Canada) 31Z0298 31Z0298 18
92 Tray Support 40C0950 40C0950 13
93
94 Hot Air motor Resistor 50R N/A 30Z1165 12
95 Diode assy with leads 11M0325 11M0325 10
Description
Door Assembly Garland 11C0336 11C0336 13
Door Assembly Tim Hortons 11C0380 11C0380 13
Door Assembly Unbranded 11C0418 11C0418 13
208V 240V
Part No
Page No
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 20
Page 21
PRINCIPAL COMPONENTS: Part Number Identification Chart 3
No
96 Side Panel Left Side 790002 790002 14
97 Side Panel Right Side 790003 790003 14
98 Top Panel 790005 790005 14
99 Foot 32Z1052 32Z1052 14
100 Wire Shelf 40C1011 40C1011 14
101 Crumb Tray RBR290X02 RBR290X02 14
102 Hot Air Fan MC3111 MC3111 14
103 Hot Air Fan Securing Nut 105065 105065 14
104 Twin Blower Resistor 39R N/A 30Z1164 12
105 Twin Blower Resistor 50R N/A 30Z1165 12
106 Flat Washer S/S M5 x 20 104036 104036 13
107 Nylon Washer 104250 104250 13
108 Spring Washer 31Z5005 31Z5005 13
109 Flat Washer S/S M6 x 20 104054 104054 13
110 Door Spacer Kit 10C0171 10C0171 28
111 Rear Outer Panel 40C0951 40C0951 14
Description
208V 240V
Part No
Page No
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 21
Page 22
PROCEDURE FOR MICROWAVE LEAKAGE TEST (1)
Warning
Check for radiation leakage after servicing. Should the leakage be more than 4mW/cm² Inform
Garland 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.
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.
Please Note
DO NOT attempt to carry out the following procedure
unless you have the following tools.
Tools required for microwave leakage test
Tim Hortons
600ml glass beaker
Supply of cold water
Microwave leakage meter
To carry out this test the Icon Pads
need to be switched to
ENGINEERING MODE PROGRAMS
See Appendix 1
Read and understand all of these notes and procedure before carrying out this operation.
Note before measuring.
• Make sure that the survey meter you are using has been calibrated and is suitable for
measuring frequencies of 2,450 MHz.
• Do not exceed meter full scale deflection, leakage meter should initially be set to the
highest scale, then adjusted down as necessary to ensure that low readings are measured
on the most sensitive range.
• To prevent false readings, hold the probe on the grip provided and move along the areas
indicated on the following page. The probe should be moved at 1 inch/second (2.5cm).
• With any casework removed the leakage should not exceed 4mW/cm².
• When measuring the leakage, always hold the probe at 2” (50mm) from the test area using
the probe supplied with the instrument.
• Always hold the probe at right angles to the oven and point of measurement.
Procedure
1 Place 275ml of cold water in the 600ml glass beaker.
2 Place the 600ml glass beaker in the centre of oven.
3 Close the door and set time for 30 seconds then press Power pad 100%
(change water every 30 seconds to prevent boiling).
Tim Hortons: In ENGINEERING MODE (see Appendix 1 ) press Pad 01 then any Load pad
(QUARTER, HALF, FULL) watch time display and open door at 30 seconds.
4 Set the leakage meter to the appropriate scale/range.
5 Move the survey meter probe along the areas indicated in (Figures 1 to 4 page 23).
6 Remember to change the water after 30 second since water that boils will result in
inaccurate readings.
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 22
Page 23
PROCEDURE FOR MICROWAVE LEAKAGE TEST (2)
• Readings must be below 4mW/cm². If a level greater that 4mW/cm² is observed,
this should be reported to Garland 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. This should be kept with the service documentation.
Control Panel - Figure 2
Door Perimeter - Figure 2
Rear and Side Covers - Figure 1, 3 & 4
Left & right Side Air Filters. - Figure 3 & 4
Test for microwave leakage at all points marked with a
Fig. 1
Fig. 3
Fig. 2
Fig. 4
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 23
Page 24
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.
Tim Hortons Ovens
To carry out this test the Icon Pads need to be switched to ENGINEERING MODE PROGRAMS
See Appendix 1
1 Fill one beaker ( glass or plastic ) with one litre ( 1.78 pints ) of tap water ( at about 68ºF/
20ºC ) and measure the water temperature.
( Use a thermometer with a
2 Place the beaker in the centre of the cavity.
3
General Market Models
Set Time to 1 minute 3 seconds and Power to 100%
Wait until the counter reaches zero.
Tim Hortons Ovens
With the oven in ENGINEERING MODE ( see Appendix 1) Press Pad 01 (Cake) and any
Load Pad ( Quarter, Half, Full ) Wait until the counter reaches zero.
4 Take the beaker out immediately stir the water with a plastic implement and measure the
water temperature.
5 Calculate the temperature rise of water in the beaker. The temperature rise of the water
should be within the following range:
Temperature Rise
27ºF ( 15ºC ) Minimum
36ºF ( 20ºC ) Maximum
Power Output is affected by the line voltage under load.
For correct Power Output measurement, the line voltage under load must be correct.
1
/10, 0.1 degree gauge ).
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 24
Page 25
PROCEDURES FOR PRINCIPAL COMPONENTS TEST (1)
1. Power Transformer 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 secondary winding
and filament winding of the Power Transformer. 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.
WARNING: Even when the oven is not cooking, the Power Transformer has High
Voltages present because of the Soft Start circuit. Isolate the oven
before testing.
See Safety Code ( Page 4 )
1 Isolate the oven from the mains supply.
2 Ensure that the High Voltage Capacitor is discharged before commencing work.
3 Remove all connections from the Power Transformer.
4 Using a D.M.M., check the resistance of the windings. Results should be as follows:
Mains winding (between tags)
High Voltage winding (between tag and chassis)
Filament winding (between terminals)
5 Using a Megger, test the insulation resistance between:
Primary winding and chassis
Filament winding and chassis
One end of the High Voltage winding is connected to the chassis, so this is not tested.
Approximately 1.1 Ω
Approximately 60 Ω
Less than 1 Ω
Pass if over 10 MΩ
Pass if over 10 MΩ
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 25
Page 26
PROCEDURES FOR PRINCIPAL COMPONENTS TEST (2)
2. 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.
WARNING: Even when the oven is not cooking, the High Voltage Capacitor has High
Voltages present because of the Soft Start circuit. Isolate the oven before testing.
See Safety Code ( Page 4 )
1 Isolate the oven from the mains supply.
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
Between Terminals
Pass if approximately 10 MΩ
Between Terminals and Case Pass if open circuit
5 Using a Megger, test the insulation resistance between the terminals and the case.
Between Terminals and Case
3. High Voltage Rectifier Test
You will need:
Pass if over 100 MΩ
A Megger or similar resistance meter using 500V d.c.
WARNING: High voltages and large currents are present at the High Voltage Rectifier.
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 .
WARNING: Even when the oven is not cooking, the High Voltage Rectifier has High
Voltages present because of the Soft Start circuit. Isolate the oven before testing.
See Safety Code ( Page 4 )
1 Isolate the oven from the mains supply.
2 Ensure that the High Voltage Capacitor is discharged before commencing work.
3 Remove all connections from the High Voltage Rectifier.
4 Using the Megger, test for continuity in both directions. Compare results with following
Open Circuit both ways
Conducts one way only
Short Circuit both ways
Conducts one way, leaks the other
Mealstream Ovens Pt. No. 32Z3403 Issue 15
FAIL
PASS
FAIL
FAIL
Page 26
Page 27
PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND 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
L1
Power In
L2
1. Monitor switch ( 14 ,Top left-hand Side ). The Monitor switch will produce
a short circuit across the mains supply if the Primary interlock switch is
faulty, when the door is opened, thus blowing the microwave fuse and
rendering the oven inoperative.
2. Primary Interlock ( 11 , Bottom left-hand ) and Secondary Interlock
( 17 , Bottom right-hand ) Switches. Operate simultaneously.
The Primary switch will cut off the microwave emissions from the oven when
the door is opened by breaking the electrical supply circuit to the
transformers. The Secondary interlock switch will cut off the microwave
emission if the Primary switch have failed.
Note:
If operation of the Monitor switch has caused the Microwave Fuse to blow,
the Primary and Monitor microswitches must be changed, as they may have
been damaged by the high short-circuit currents involved.
Primary switch
11
17 Secondary switch
Power Out
14 Monitor switch
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 27
Page 28
PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST (2)
Please Note
DO NOT attempt to carry out the following procedure
unless you have the following tools and parts.
Continuity Meter
Door Spacer Kit
Part No. 10C0171
Spacer No. required Part No.
S10 Door Spacer 10mm
S5 Door Spacer 5mm
S1 Door Spacer 1mm
2 40C1119
2 40C1118
2 40C1114
WARNING
Before starting this test procedure please make sure that the oven is disconnected
from the electrical supply and that the oven power switch (ON/OFF) is in the OFF
position.
After each step check that the interlocks are operating in the correct order using a
continuity meter.
See Safety Code ( Page 4 )
Disconnect the microswitches and check for the continuity of the switches with a continuity meter
Step 1: Set the interlock so that they activate in the following order.
When closing the door.
Interlock Order
SW1 (Monitor) 1st
SW2 (Primary) 2
SW3 (Secondary) 2
When opening the door.
Interlock Order
SW1 (Monitor) 3rd
SW2 (Primary) 1
SW3 (Secondary) 1
nd
Note both SW2 and SW3 activate together
nd
Note both SW2 and SW3 activate together
st
Note both SW2 and SW3 activate together
st
Note both SW2 and SW3 activate together
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 28
Page 29
PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST (3)
Step 2: Insert S10 10mm spacer into door.
(See figure 1 below for inserting spacer
correctly).
Step 3: Remove S10 10mm spacer and insert S1 1mm
spacer into the door and close the door.
Step 4: Remove S1 1mm spacer and insert S5 5mm
spacer into the door and close the door.
If an oven fails this sequence
then check the microswitches are functioning
Interlock Order
SW1 (Monitor) CLOSED
SW2 (Primary) OPEN
SW3 (Secondary) OPEN
Interlock Order
SW1 (Monitor) OPEN
SW2 (Primary) CLOSED
SW3 (Secondary) CLOSED
Interlock Order
SW1 (Monitor) OPEN
SW2 (Primary) OPEN
SW3 (Secondary) OPEN
correctly and repeat steps 1 to 4.
After carrying out this procedure make sure that the interlock monitor switch is properly connected
according to the circuit diagram on pages 44-46.
Figure 1
Door side seal
Door top seal
Door spacer
The door spacer must always be
located on the point where the side
seals and top seals meet.
Please note.
It is very important after completing this procedure to carry out a
microwave leakage test procedure. See pages 22-23.
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 29
Page 30
PROCEDURE FOR BUILDING AND FITTING MEALSTREAM DOOR
Parts required for door fitting
Please Note
DO NOT attempt to carry out the following procedure
unless you have the following tools and parts.
Item No. Description Part No. Quantity
1 RHS door hinge assy 11C0166 1
2 M5 x 10mm 101820 4
3 M5 flat washer 31Z5008 29
4 M5 shake proof washer 31Z5012 29
5 Spacer 790084 2
6 M5 x 16mm hex screw 101876 2
7 Door frame assy 11C0303 1
8 LHS door hinge assy 11C0167 1
9 Door arm assy 11C0300 2
10 Door arm Pivot Pin 790010 2
11 Door spring 520000 or 40C1141 2
12 Door Stop 40C0854 2
13 Door stop spring clip 31Z5047 2
14 M5 stainless steel full nut 80X07003 23
15 Door seal set of 4 11C0292 1
16 CAF 30 Adhesive 31Z0186 As required
17 Door insulation set 40C0942 1
18 Outer Door Skin Check Oven Model 1
19 M3 counter sunk screw 31Z3094 7
20 Choke Plate 790007 1
21 SPACER KIT 10C0171 1
Tools required for door fitting
M5 Nut runner Door Spacers S325 & 3 off S215
Flat head screw driver Long nose pliers
5mm open-ended spanner Adhesive skeleton gun
Engineers rule
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 30
Page 31
PROCEDURE FOR BUILDING AND FITTING MEALSTREAM DOOR
1. Visually check all parts to be used.
2. Fit right hand side (RHS) Hinge assy. to base
assy. loosely fit in place with bottom bolts, 2
off M5 x 10mm, 2 off M5 flat washer, 2 off M5
shockproof washer.
Fit spacer to fill gap between Hinge assy and
Inner side panel, loosely fit spacer in place
with 1 off M5 bolt x 16mm, 1 off M5 flat
washer, 1 off M5 shakeproof washer.
3. Insert (RHS) Pivot pin of door frame into
(RHS) Hinge assy. Place door frame against
cavity face and slide on (LHS) Hinge assy to
the (LHS) Pivot pin of door frame,
Spacer
Hinge
fixings
4. Fit right hand side (RHS) Hinge assy to base
assy, loosely fit in place with bottom bolts, 2
off M5 x 10mm, 2 off M5 flat washer, 2 off M5
shockproof washer. Fit spacer to fill gap
between Hinge assy. and Inner side panel,
loosely fit spacer in place with 1 off M5 bolt x
16mm, 1 off M5 flat washer, 1 off M5
shakeproof washer.
Pivot
pin
Pivot pin
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 31
Page 32
PROCEDURE FOR BUILDING AND FITTING MEALSTREAM DOOR
5. Fit door frame assembly (including seals
and cage nuts) firmly against cavity and
tighten all fixing bolts to secure (RHS)
and (LHS) Hinge assy.
Hinge
6. Position door frame central by using the
following method.
Measure the distance between the side of the
door and the TDK Mounting Strip on both
sides with the door in the closed position.
Add these two measurements together and
divide by 2. Adjust hinge adjustment bolt so
the door is the distance calculated from the
TDK Mounting Strip and lock in position with
lock nut.
TDK
Mount
Door
7. Fit (RHS) and (LHS) door arms through slots
in cavity and insert door arm pivot pins
through door arms into door frame.
Door arm pivot pin
8. Fit door springs to door arms and to the hook
at base of inner side panels. Check operation
of door and remove (LHS) spring.
Door hinge adjustment
Spring clips
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 32
Page 33
PROCEDURE FOR BUILDING AND FITTING MEALSTREAM DOOR
9. Position door choke to Door Frame Assembly
making sure it is in the correct orientation (the
top of door choke is marked with ‘T‘ on the
underside).
‘T’
Mark
10. Loosely fit 3 off M5 flat washers, 3 off M5
shockproof washers, and 3 off M5 stainless
steel full nuts.
11. Tape choke Spacer S325 to the cavity base and
tape choke Spacers S215 to sides and top of
door choke.
Close the door and centralise the door choke.
Fit the remaining 20 M5 washers and nuts
tighten the fixings evenly.
Stage 1
3
Stage 2
1
4
1 Cavity base S325
2 Choke fingers Top S215
3 Choke fingers Left S215
4 Choke fingers Right S215
Remove spacing pieces and check door
operation.
Mealstream Ovens Pt. No. 32Z3403 Issue 15
2
Page 33
Page 34
PROCEDURE FOR BUILDING AND FITTING MEALSTREAM DOOR
12. Fold the square piece oven insulation in half
and place it in the recess in the oven door.
Place the rectangular piece into the remainder
of the door (foil facing out).
13. Place the outer skin over the door frame
assembly and fix with 7 of M3x12 counter sunk
screws around the LHS, RHS and top of the
door.
Please note.
It is very important after completing this procedure,
to carry out a Door interlock adjustment and test procedure.
See pages 27-29.
Stage 1
Stage 2
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 34
Page 35
PROCEDURE FOR REPLACING DOOR SEAL ASSEMBLY (1)
Parts required for replacing carbon loaded door seals
Please Note
DO NOT attempt to carry out the following procedure
unless you have the following tools and parts.
Item Description Part Number Quantity
1 Door seal set of 4 11C0292 1
2 CAF 30 ( Black ) 31Z0186 As required
Tools required for replacing carbon loaded door seals
Long nose pliers
Adhesive skeleton gun
Flat head screw driver
Please note.
Before proceeding with this procedure ensure that the oven is disconnected
from the power supply.
If the oven has been operating recently please allow time for the oven to cool.
Removing Door seal
1 Open the oven door.
2 Use a pair of long nose pliers to unclip one end of the seal. (See figure 1 page 36)
3 Peel back the door seal assembly and unclip at the other end. (See figure 2 page 36)
4 Remove the residue CAF 30 adhesive with a flat head screw driver. (See figure 3 page 36)
5 Visually inspect the vitreous enamel to ensure that it is undamaged.
Fitting a New Seal
1 Clip on end of the door seal in place. Using a pair of long nose pliers, stretch the door seal
and connect the other end in place. (See figure 4, 5 & 6 page 36)
2 Visually inspect that the door seal is sitting in the rebate provided.
3* Perform door interlock set-up procedure (See page 27-29)
4* Perform a microwave leakage test procedure. (See page 22-23)
5 Lift the seal and applied a thin line of CAF 30 adhesive along the length of the rebate and
push the seal down. (See figure 7 page 36)
6 Seal the ends of the door seal with CAF 30 (See figure 8 page 36)
Leave the door in the open position to allow the adhesive to set.
* It is very important to carry out these procedures
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 35
Page 36
PROCEDURE FOR REPLACING DOOR SEAL ASSEMBLY (2)
Figure 1
Figure 3
Figure 2
Figure 4
Figure 5
Figure 7
Figure 6
Figure 8
Please note.
It is very important after completing this procedure,
to do a Door interlock adjustment and test procedure.
See pages 27-29.
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 36
Page 37
PROCEDURE FOR REMOVING SHELF RUNNERS AND ELEMENT COVER PLATE
Please Note
DO NOT attempt to carry out the following procedure
unless you have the following tools.
Tools required for removing shelf runners and element cover plate.
M6 nut runner
M5 nut runner
M6 x 12mm
stainless steel Hex
Head screw
Pt No. 80T7133
Shelf runner
1. Loosen the rear fixings screws of both shelf runners with M6 nut runner.
2. Remove the front fixings screws of both shelf runners with M6 nut runner.
3. Pull the shelf runners forwards away from the rear screws.
4. Remove the 4 off M5 dome nut securing the Element cover plate.
5. Lift the Element cover plate out taking care to not damage the temperature sensor pocket.
M5 stainless steel
dome nut
Pt. No. 80X7025
Element cover plate
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 37
Page 38
PROCEDURE FOR REPLACING HEATER ELEMENT
Please Note
DO NOT attempt to carry out the following procedure
unless you have the following part and tools.
Parts required for replacing heater element.
Item Description Part Number Quantity
1 Heater Element 208 volt 40C0949 / 240 volt 40C0948 1
2 Mesh Washer 31Z5044 3
Tools required for replacing heater element.
M5 nut runner
1. Disconnect or isolate oven from mains supply.
2. Remove outer covers.
3. Remove shelf runners and element cover plate
( See page 37 ).
4. Disconnect wires from heater element terminals at rear of
oven.
5. Remove M5 screw securing heater element.
6. Remove heater element.
7. Refit new heater element with new mesh
washers fitted over each terminal and 3 off
M5 Flat washer over the M5 screw (this is
very important to prevent microwave
leakage).
8. Tighten M5 screw and check that the
heater element is not touching the
cavity or protruding to much that it
will not touch the element cover plate.
9. Reconnect wires to heater element terminals
at rear of oven.
10. Replace element cover plate and shelf runners.
11. Perform Microwave Leakage procedure
(see page 22-23) checking carefully around
the heater element terminals at rear of oven.
12. Replace outer covers and fully test oven.
Heater Element
M5 x 25mm Hex head
S/S screw Pt. No. 101825
3x M5 Flat
Washers
Mesh
Washers
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 38
Page 39
PROCEDURE FOR REPLACING HOT AIR MOTOR ASSEMBLY
Please Note
DO NOT attempt to carry out the following procedure
unless you have the following part and tools.
Parts required for replacing hot air motor assembly.
Item Description Part Number Quantity
1 Hot Air Motor Assembly 11C0312 1
Tools required for replacing hot air motor assembly.
M5 nut runner
1. Disconnect or isolate Oven from mains supply.
2. Remove outer covers.
3. Remove shelf runners and element cover plate (See page 37).
4. Remove fan blade securing nut and remove fan blade.
5. Disconnect motor connection at terminal block.
(Note: which wire colour goes to which terminal).
6. Disconnect Motor Earth tag then undo all securing nuts from the
motor mounting plate and remove the fan motor assembly.
7. Check the position and condition of the hot air motor damper/seal
(this a important microwave leakage seal) in the motor shaft
screen. (See page 17).
8. Fit new hot air motor assembly, and fit all securing washers and
nuts, ensure it is aligned centrally into the hole in the cavity, and
tighten all securing nuts. Make sure the ground wire is connected.
9. Reconnect motor connection at terminal block.
(Note: correct position of each wire colour).
10. Refit fan blade and fan blade securing nut, and ensure that the
fan/motor rotates free by hand.
11. Refit shelf runners and element cover plate.
12. Perform Microwave Leakage procedure (see pages 22-23),
checking carefully around the hot air motor assembly at rear
of oven.
13. Replace outer covers and fully test oven.
Fan blade securing nut
Fan blade
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 39
Page 40
PROCEDURE FOR REPLACING MAGNETRON ASSEMBLY (1)
Parts required for replacing magnetron
Please Note
DO NOT attempt to carry out the following procedure
unless you have the following tools and parts.
Item Description Part Number Quantity
1 Magnetron 30Z1171 1
Tools required for replacing magnetron
Philips screw driver
M5 nut runner
WARNING
Before proceeding with this procedure ensure that the oven
is disconnected from the power supply,
And the high voltage capacitors are discharged
See Safety Code ( Page 4 )
1. Remove the top and side casing from the oven.
2. Remove the air duct cover plate.
(See figure 1 page 41)
3. Disconnect the 2 wires and earth wire from the over temperature stat and the 3 wires from
the magnetron connection block.
(See figure 2 page 41)
4. Remove the 4 nuts from the magnetron fixing.
(See figure 3 page 41)
5. Remove the magnetron.
(See figure 4 page 41)
6. Remove the 2 screws form the over temperature stat on the magnetron and remove.
(See figure 4 page 41)
7. Visually inspect the new magnetron making sure that the wire mesh gasket seal is in place
and undamaged. Check the outer casing for any damage such as dents.
(See figure 5 page 41)
8. Attach the oven temperature stat to the new magnetron.
(See figure 5 page 41)
9. Visually inspect the magnetron mount in the wave guide making sure that it is undamaged
and that there is no debris that may obstruct the new magnetron when fitted.
(See figure 5 page 41)
10. Place the new magnetron in position making sure it is in the correct orientation.
11. Replace the 4 fixing nuts making sure that they are tightened equally.
12. Reconnect the wiring to the over temperature stat.
13. Reconnect the wiring to the magnetron.
14. Replace the air duct cover.
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 40
Page 41
PROCEDURE FOR REPLACING MAGNETRON ASSEMBLY (2)
Figure 1 - 6
Figure 1
Screw
Figure 3
Temperature
Stat.
Figure 2
Temperature
Stat.
Figure 4
Magnetron
connection
block
4 x Magnetron
screw fixings
Figure 5 Figure 6
Temperature
Stat.
Screws
Wire mesh
Magnetron mount
Please note.
After completing this procedure do a microwave leakage test.
See page 22-23.
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 41
Page 42
PROCEDURE FOR TESTING MEMBRANE PANEL CIRCUIT
You will need:
A Digital Multi-meter (D.M.M.)
1. The oven isolate from the electrical supply.
2. Remove the Logic Assembly from the Control Panel Housing.
3. Unplug the membrane “tail” from the Logic PCB Assembly.
4. Using a D.M.M., check for continuity between the correct terminals when the pads are
pressed.
5. When the panel has been tested, re-assemble and re-test the control circuit.
1 10
Mealstream 501 US
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 42
Page 43
PROCEDURE FOR TESTING MEMBRANE PANEL CIRCUIT (2)
Mealstream 501 US Tim Hortons & Unbranded Variant
Note:PINS 1-4 Lower Layer & Pins 5-10 upper layer
Mealstream 501 US Tim Hortons French (Canada)
Note:PINS 1-4 Lower Layer & Pins 5-10 upper layer
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 43
Page 44
CIRCUIT DIAGRAM: ALL MODELS BEFORE 05.28.02
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 44
30Z1177
30Z1177
30Z1177
30Z1177
Page 45
CIRCUIT DIAGRAM: ALL MODELS AFTER 05.28.02-11.10.02
Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 45
Page 46
CIRCUIT DIAGRAM: ALL MODELS AFTER 11.11.02
1
3.0 KW
RHS
MAG 2
CAVITY HEAT
D
C
2
(3)U
3
NOTE
REVERSE
PHASING
N(4)
C
T2
(1)U
L(2)
MAG 1
LHS
D
T1
30Z0124
HS1
300°C
572°F
OVER HEAT
GOLD
RESISTOR
10 AMP 10 AMP
FUSE FUSE
F2 F3
11
1
A
9
of
11Monday, Nove mber 11, 2002
1
40C0952
50E123
A1
MERRYCHEF LTD
STATION ROAD WEST
ASH VALE, ALDERSHOT
HANTS GU12 5XA
TEL:+44 (0)1252 371000 FAX:+44 (0)1252 37100
Size Document Number Rev
Date: Sheet
11C0402 208V
11C0403 240V
RELAY PCB
CAVITY SENSOR
11C0291
MEMBRANE
LOGIC PCB
2
3
(3)U
4
MF3 MF4
**
BLUE
BROWN
RED
YELLOW
5
INTERLOCK
123
NO COLOR
4
TEST 3
TEST POINTS
MONITOR
6
(1)U
FILTER 3 FILTER 4
L(2)
N(4)
OVERHEAT
MAGNETRON
MS1 MS2
SECONDARYPRIMARY
OMIT
GRA1 AND GRA2
50W
GOLD
RX1 RX2
RESISTOR
ON 208V VERSION
39R
SEE NOTE 1
TEST 4
8
GRA2
39R50R
GRA1
A
15
DOOR
PSU
VOLTAGE
4
5
6
SW1
SHOWN IN DOOR
SW2 SW3
(3)U
MF1
FILTER 1
(1)U
MF2
7
(1)U
FILTER 2
OPEN POSITION
MAGNETRON
CONVECTION
COOLING FANFAN
BROWN
M4
6uF
BLUE
A
14
B
15
STIRRER
MOTOR
7
13 14 15 1097 127 32 54 166
NOTE 1: ON 240V 60HZ VERSION ONLY - 208V MAGNETRON COOLING FAN IS SUPPLIED VIA
SERIES 39R AND 50R RESISTOR AS SHOWN. ON 208V 60HZ VERSION NO RESISTORS ARE FITTED
MEALSTREAM SERIES 5 WIRING DIAGRAM 2POLE/3POLE + GND (NORTH AMERICA) FROM NOV 2002
F6
F7
N(4)
L(2)
FUSE
F1
FUSE
8
EARTH
TB1
FUSE
L1
TEST 1
L3
LINK
FOR
2POLE
D D
L(2)
N(4) (3)U
F5
FUSE
TEST 2
L2
F4
FUSE
SW4
MERRYCHEF
PART No.
30Z0217
30Z0217
30Z1177
= 20A
F1F2F3F4F5F6F7
C C
B B
FUSE RATING
= 10A
= 10A
30Z1177
30Z1177
= 1A 30Z0957
= 20A
= 20A
30Z1177
= 30Z0240
SW1
= 20A
= 30Z0240
= 30Z0240
SW2
SW3
8
OMIT FILTER 3 & 4
FOR 240V VERSION
*
Mealstream Ovens Pt. No. 32Z3403 Issue 15
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CIRCUIT DIAGRAM: ALL MODELS AFTER 04.06.03
Mealstream Ovens Pt. No. 32Z3403 Issue 15
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ERROR CODES AND DIAGNOSTICS
The Mealstream will identify some of the most common problems by flashing an error message
code in the time display window.
These are the error messages, and suggestions for repairing them.
Door not fully shut.
1
Possible electrical fault
2
Magnetron overheating.
3
Close door fully.
Door switch inoperative.
Check air filters.
Check location, air inlet
temperature and air filters.
No time has been set.
1
Invalid time has been
2
set.
Invalid program has
3
been set.
TIM HORTONS
4
No cook program
assigned to selected pad
Oven not heating up.
1
Possible Heater fault.
2
Oven Cavity overheating. Confirm heater relay is
1
Set a time.
Set a valid time.
Use call-back to check program.
Ensure correct Menukey is
installed (switch oven off then
on to show key No. )
Check heater fuse.
Confirm operation of heater
circuit.
operating.
Check sensor.
Oven is not at correct
1
temperature to start
program.
Remove food.
Allow oven to reach correct
temperature.
If the key is removed before
the download is complete or
the process is interrupted
the display shows EPS
then FAIL then REDO
Switch oven off and begin the
MenuKey download again.
See Appendix 2.
Mealstream Ovens Pt. No. 32Z3403 Issue 15
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APPENDIX 1
Tim Hortons variants: Power Test and Microwave Leakage Test (Pages 22-24)
Engineering Mode programs
In order to carry out the Power Test and Microwave Leakage Test on Tim Hortons
variant Ovens, the Icon Pad programs on the control panel need to be switched to
Engineering Program Mode.
Engineering Mode does not affect the current Menukey program settings for the Icon
pads and the current Menukey programs are automatically restored when the oven is
next switched on.
To switch to Engineering Mode Programs:
1 With the oven switched off hold down the CANCEL ( ANNULER ) Pad and switch the oven
ON, the display shows the current Menukey Code, continue to hold the CANCEL
( ANNULER ) Pad for approximately 10 seconds until the display shows
indicating the oven is now in engineering mode
2 Programs will be set as follows:
EE 00:00
Program Number Time Temp Power
Pad 01 1 minute 3 secs Off 100%
Pad 02 3 minutes Off 100%
Pad 03
Pad 04
All other programs will be blank
3 Follow the Leakage Check Procedure as detailed on pages 22-23, using Program 01
( Cake ) to give the required 1 minute 3 seconds at 100% Microwave Power setting.
4 Follow the Power test procedure as detailed on Page 24 using Program Pad 01 ( Cake) to
give the required 1 minute 3 seconds at 100% Microwave Power setting.
5 On completion the current Menukey programs are automatically restored when the oven is
next switched on.
Stage 1 30 minutes 480 °F 100%
Stage 2
59 minutes 59secs 480 °F None
29 minutes 59 secs 480 °F 50%
Mealstream Ovens Pt. No. 32Z3403 Issue 15
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APPENDIX 2: 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.
1
Lift the MenuKey™ cover in the top panel
2
of the oven and put the key in the keyhole
Turn the key clockwise to the stop
( ¼ turn ).
Do not remove the key at this stage.
3
Switch the power switch on.
The oven will now go through the program
download sequence by displaying the
following:
The Key Code
The number of
programs and each
program number on the key.
When the display shows 0:00, the cavity
lights up and the fans start.
Remove the key and close the cover and
the oven is ready to use with the new
programs.
To confirm the download is successful
Switch off the oven.
Switch on and the display briefly will show the following:
1. The new key code
2. 0:00 (oven ready to use)
example: Key 01
example: 38 programs
EPS-FAIL-REDO
If the key is removed before
the download is complete or
the process is interupted the
display shows EPS then FAIL
then REDO
Switch oven off and begin the
MenuKey download again.
Mealstream Ovens Pt. No. 32Z3403 Issue 15
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APPENDIX 3: TEMPERATURE SENSOR RESISTANCE DATA
Temperature Sensor Resistance
Temp °F Temp °C Min. Rate
kΩ
212 100 11.490 13.060 14.810
302 150 2.803 3.161 3.434
392 200 0.950 1.000 1.050
482 250 0.3572 0.3865 0.4171
Standard
Rate kΩ
Max. Rate
kΩ
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.
Mealstream Ovens Pt. No. 32Z3403 Issue 15
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MANUAL CORRECTIONS AND MODIFICATIONS
Whilst every effort has been made to ensure that the information contained in this manual is
accurate and complete, if you believe that an error has been made, or if you have any
suggestions for how the manual could be improved, please fill in and return this form. A review of
any forms returned will be made on a regular basis, and the manual will be updated if required.
Name
Address
Page number on which error occurs (if applicable) - Mealstream Garland
Description of error
Suggestion for improvement to manual
Please return this form to:
Garland Commercial Industries
1177 Kamato road
Mississauga
Ontario L4W 1X4
CANADA
Attn : Service Department
Or Fax it on 800-361-7745
Mealstream Ovens Pt. No. 32Z3403 Issue 15
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