Merrychef CTM5MTV Operators Manual
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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 & cavity roof ............................. 13
Principal components: External Parts & accessories............ 14
Principal components: Cavity Parts ..................................... 15
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
Error codes and diagnostics.................................................. 45
Appendix 1: Test Procedure for Tim Hortons........................ 46
Appendix 2: MenuKey® Download procedure ...................... 47
Appendix 3: Temperature Sensor resistance data ................ 48
Appendix 4: Cleaning Procedure .......................................... 49
Appendix 5: Hot Air Motor Upgrade ...................................... 50
Appendix 6: Recommended Spares List ............................... 51
Appendix 7: Door stop & Adjustable microswitch bracket ..... 52
Appendix 8: Door arm guide ................................................. 53
Manual corrections and modifications................................... 5
4
Mealstream Ovens Pt. No. 32Z3403 Issue 16
Page 2
MICROWAVE SAFETY PRECAUTIONS
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.
(i) A microwave leakage check to verify compliance with the Federal
(e)
Performance Standard should be performed on each oven prior to
release to the owner. For U.S.A.
(ii) A microwave leakage check to verify compliance with the Canadian
(e)
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 16
Page 3
Ω
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 M
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.
Resistor.
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 inches ( 50mm ) above.
Air flow should not be restricted. (see page 6 installation).
Mealstream Ovens Pt. No. 32Z3403 Issue 16
Page 4
PRODUCT SPECIFICATIONS
Model Number: + Voltage + Frequency + Phases + Controls + Country
Model No. CTM3
Voltage
208V 20
240V 24
Frequency
Phases
Control Type
Country
Customer Variant
Power
Requirements
208Volts
240Volts
Power Output Microwave 100%
Convection
Combination
External
Height
Dimensions
Width
Depth
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
Height
recommended
clearances
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 16
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
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.
Positioning the Oven
Canada models
US models
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 16
Page 6
MAIN FEATURES
a
b
c
d
e
k
On/Off SWITCH
a
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.
OVEN CAVITY
c
The oven cavity is mainly constructed
from stainless steel panels. It must be
kept clean.
HOT AIR FAN
f
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.
RATING PLATE
g
The rating plate is situated on the rear of
the oven, and states the Model, Serial
Number, Electrical Ratings and
Manufacturers telephone number.
b
f
g
j
i
h
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 16
DOOR
h
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.
DOOR SEAL
i
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
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
fg
N
Tim Hortons control panel
K
L
Program Pad
j
Menukey™
N
Preheat
K
Cancel
L
Icon Cook Pads
M
MenuKey™
N
M
a
b
M
O
N
MENU
KEY
Quarter, Half & Full Batch Load
O
Mealstream Ovens Pt. No. 32Z3403 Issue 16
Page 8
PRINCIPAL COMPONENTS
Left side
1
1A
2
2A
3A
3
4
4A
14
118
5
5A
6
13
12
7
11
118
8
10
9
112
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 40C1141 40C1141
9 Door springA Modification Kit 10C0177 10C0177
10 Door arm stop assembly
11 Microswitch ( Primary ) 30Z0240 30Z0240
12 Door hinge assembly ( LH )
13 Door arm assembly 11C0300 11C0300
14 Microswitch ( Monitor ) 30Z0240 30Z0240
112 Internal Filter LHS 40C0962 40C0962
118 Microswitch support bracket 40C0851 40C0851
C
B
11C0279 11C0279
11C0167 11C0167
Mealstream Ovens Pt. No. 32Z3403 Issue 16
Note A:
Ovens before
June 2003
Note B:
See page 17 for
parts
Note C:
For ovens later
than May 2005
See Appendix 7
Page 9
PRINCIPAL COMPONENTS
Right side
59
13
16
95
22
21
20
90
17
910
113 118
No Description 208V 240V
9 Door spring 40C1141 40C1141
9 Door spring Kit
10 Door arm stop assembly
13 Door arm assembly 11C0300 11C0300
16 Door hinge assembly ( RH )
17 Micro-switch ( Secondary ) 30Z0240 30Z0240
20 Steam pipe 790046 790046
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 11M0417 11M0417
113 Internal Filter RHS 40C1080 40C1080
118 Microswitch support bracket
Note C: Ovens after May 2005 see Appendix 7
A
C
B
C
10C0177 10C0177
11C0279 11C0279
11C0166 11C0166
40C0851 40C0851
Note A:
Ovens before
June 2003
Note B:
See page 17 for
parts
Mealstream Ovens Pt. No. 32Z3403 Issue 16
Page 10
PRINCIPAL COMPONENTS
Top view
87
23
24
63
26
27
60 61
87
23
24
63
26
27
28
62
No Description 208V 240V
23 Magnetron (Panasonic) 30Z1171 30Z1171
24 Resistor 470 R 30Z0283 30Z0283
26 Capacitor 0.88μf (2300V)
26 Capacitor 0.88μf (2500V) Kit 10C0172 10C0172
27 Transformer
28 Twin blower motor 30Z1145 30Z1145
60 25mm OD Flexible conduit 314402 314402
61 20mm OD Flexible conduit 314401 314401
62 Capacitor clip (88mm) 30Z0521 30Z0521
63 Filter 30Z0997 N/A
87 Magnetron Thermal Trip 2571016 2571016
Note D: This Capacitor is replaced with 30Z1251 0.88μf 2500V and 2 x 88mm
clips 30Z0521 included in a service kit Part No. 10C0172
Note E: All transformers are now replaced by the Multi-tap type Part No. 30Z1230
E
D
30Z0861 30Z0861
30Z1230 30Z1230
Mealstream Ovens Pt. No. 32Z3403 Issue 16
Page 11
PRINCIPAL COMPONENTS
Back view
94
88
64
65
104
No Description 208V 240V
64 Hot air motor assembly 10C0192
65 Capacitor (motor start ) 6μF 30Z1148
88 Overheat Safety Thermostat 30Z1024
94 Hot Air motor Resistor Assy N/A
104 Twin Blower Resistor Assy N/A
10C0192
30Z1148
30Z1024
11C0341
11C0477
Mealstream Ovens Pt. No. 32Z3403 Issue 16
Page 12
PRINCIPAL COMPONENTS
Door and cavity roof
86
72
72
71
86
67
114
106
107
77
108
109
89
No Description 208V 240V
53 M5 Hex/hd s/s Screw 101825 101825
67 Stirrer glass assy. ( inc. long seals ) 11C0319 11C0319
71 Door seal kit 11C0292 11C0292
72 Door choke 790007 790007
76 Door Handle Towel Rail 32Z1064 32Z1064
77 Bolt 1/4" 20 UNC 3/4" Hex 109050 109050
86 Cavity roof seal (short) 790052 790052
89 Door Handle 40C1020 40C1020
93
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
117 Nut M4 S/S 31Z4015 31Z4015
Door Assembly Garland 11C0336 11C0336
Door Assembly Tim Hortons 11C0380 11C0380
Door Assembly Unbranded 11C0418 11C0418
76
Mealstream Ovens Pt. No. 32Z3403 Issue 16
Page 13
PRINCIPAL COMPONENTS
External Parts and accessories
100
121
98
122
96
111
123
97
114
99
116
No Description
96 Side Panel Left Side 790002 40C1182
97 Side Panel Right Side 790003 40C1183
98 Top Panel 790005 40C1181
99 Foot 32Z1052 32Z1052
100 Wire Rack 40C1011 40C1011
101 Crumb Tray RBR290X02 RBR290X02
111 Rear Outer Panel 40C0951 40C1180
114 Side bumper RMC6104 RMC6104
116 Air filter panel (removable) 40C0868 40C0868
119 Push fit bumper ( Rear Panel ) 31Z1187 31Z1187
121 Roof Corner cap n/a 40C1113
122 Front pillar LH n/a 40C1184
123 Front pillar RH n/a 40C1185
All models before
February 2004
All models
after February 2004
101
119
Mealstream Ovens Pt. No. 32Z3403 Issue 16
Page 14
PRINCIPAL COMPONENTS
Heater Element and Cavity parts
No Description 208V 240V
57 Mesh washer 31Z5044 31Z5044
68 Heater element 40C0949 40C0948
69 Heater element
cover plate
70 Baffle 11C0311 11C0311
85 Dome Nut 80X7025 80X7025
92 Shelf Support (Garland) 40C0950 40C0950
102 Hot Air Impeller 10C0236 10C0236
115 Shelf Support
Tim Hortons
124 Shelf support fixing bolt 80T7133 80T7133
790047 790047
10C0174 10C0174
Electronic Control Panel Assembly
29
33
57
68
102
70
85
124
70
115
125
69
92
Tim Hortons
92
32
31
34
73
30
No Description 208V 240V
29 On/Off Switch 30Z0503 30Z0503
Tim Hortons
See page 16
30 Control Panel Assy with Menukey
(except Tim Hortons)
31 Logic Board (except Tim Hortons) 11C0377 11C0377
11C0379 11C0379
32 Relay Board (except Tim Hortons) 11C0316 11C0212
33 AC Ribbon connector (6 way) 11M0116 11M0116
34 DC Ribbon connector (10 way) 11M0360 11M0360
73 MenuKey Assembly 10C0148 10C0148
125 PCB standoff 2243033 2243033
Control Panel Assembly on ovens manufactured before February 2004
Control panels now supplied are for the new style casework and not compatible with older models.
When replacing the control panel assembly remove the top trim/On-Off switch metal panel from the
existing control panel and substitute this for the top trim on the replacement unit.
Mealstream Ovens Pt. No. 32Z3403 Issue 16
Page 15
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 16
Page 16
PRINCIPAL COMPONENTS
( not shown in main views )
54
53
Left Hand Door Hinge
12
Assembly
52
51
55
58
Right Hand Door Hinge
16
52
51
56
Stirrer motor assembly
Assembly
54
53
No. Description All models
12 Door Hinge Assembly LH 11C0167
16 Door Hinge Assembly RH 11C0166
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 11C0324
Mealstream Ovens Pt. No. 32Z3403 Issue 16
Page 17
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