Merrychef e4 User Manual

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Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

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eikon e4

Service & Parts Manual

CAUTION MICROWAVE EMISSIONS:

DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY.

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

SYMBOLS

The symbols below are used, where applicable, as visual guidance throughout this manual.

DANGER

This symbol is shown if there is a high risk of severe personal physical injury. The relevant safety precautions MUST be observed and implemented at all times.

WARNING

This symbol is shown if there is a possible risk of personal physical injury or if damage may occur to the equipment. The relevant safety precautions MUST be observed and implemented at all times.

INFORMATION

This symbol is used to highlight useful or important information. For example: The manual consists of main sections (tab markers on the extreme left and right of the pages), followed by the main subject heading, sub-headings and text. Text with a reference number or letter, such as (1) refers to the same reference on the image.

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

SAFETY &

REGULATIONS

PRODUCT

DETAILS

TESTING

COMPONENTS

SERVICINGSPARES &

REPLACEMENT

FAULT FINDINGELECTRICAL

CIRCUITS

COMMISSIONING

CONTENTS

SAFETY & REGULATIONS

1 SAFETY REQUIREMENTS 4

1.1 Important: 4

PRODUCT DETAILS

2 PRODUCT OVERVIEW & FUNCTIONS 5

3 MAIN FEATURES 6

4 TECHNICAL SPECIFICATIONS 7

4.1 Specications 7

4.2 Serial Number (Rating Plate): 7

5 INSTALLATION 8

5.1 OVEN LOCATION AND POSITIONING 8

6 ELECTRICAL INSTALLATION 9

7 QUICK START GUIDE: QUICK SERVICE OVEN 10

7.1 START UP 10

7.2 USING A COOKING PROGRAM 11

8 OPERATING GUIDE: FULL SERVICE OVEN 12

8.1 easyToUCH MAIN MENU & KEYBOARD SCREEN 12

8.2 DEVELOPMENT MODE: CREATING A COOK PROGRAM 13

8.3 PRESS & GO 14

8.4 USING A COOKBOOK PROGRAM 14

8.5 CHANGING THE OVEN TEMPERATURE 15

8.6 VIEWING & EDITING PROGRAMS 15

8.7 ADDING A NEW PROGRAM GROUP 16

8.8 MOVE A PROGRAM WITHIN A PROGRAM GROUP 16

8.9 ADDING A PROGRAM TO A GROUP 17

8.10 MANAGING PROGRAM GROUPS 17

9 OVEN CONTROL SETTINGS 18

9.1 Oven mode/navigation settings (A) 18

9.2 Language options (B) 18

9.3 Oven temperature settings and labels (C) 18

9.4 Recipe counters (E) 19

9.5 Date and Time settings (F) 19

9.6 Sound levels (G) 19

9.7 Oven Timer (H) 19

9.8 USB oven programs (J) 20

9.9 Restore Factory Defaults (K) 20

9.10 Temperature Band (L) 20

9.11 Change Password (M) 20

10 COOLING THE OVEN DOWN BEFORE CLEANING 21

10.1 Oven cool down 21

10.2 Preparing to clean the oven 21

11 Cold oven CLEANING INSTRUCTIONS e4 22

SERVICING

12 SERVICING THE OVEN 23

12.1 Servicing Procedure: 23

12.2 Enter Service mode: 23

13 ERRORS & DIAGNOSTICS 24

13.1 ERROR MESSAGES 24

13.2 COPYING ERROR MESSAGES: 24

13.3 ERROR LOG 24

13.4 OVEN COUNTERS 24

13.5 VISUAL VIEW 25

14 FIRMWARE UPDATES 26

TESTING COMPONENTS

15 OVEN TESTING 29

15.1 Equipment required 29

15.2 Earth/Insulation Test: 29

15.3 Screen calibration: 29

15.4 OVEN TESTS 30

15.5 Microwave Power Test 30

15.6 Microwave Leakage Test 31

15.7 Temperature Control Test 32

15.8 Soak Test 33

15.9 Recommission Test 33

16 HIGH VOLTAGE COMPONENTS 34

16.1 Power Transformer Test 34

16.2 High Voltage Rectier Test (Diode Board) 34

16.3 High Voltage Capacitor Test 35

16.4 High Voltage Magnetron Test 35

17 MAINS VOLTAGE COMPONENTS 36

17.1 Door Interlock Adjustment 36

17.2 Convection Fan Motor & Controller 37

SPARES & REPLACEMENT

18 OVEN COMPONENTS 38

19 SRB & BTS Circuit Boards 40

19.1 SRB replacement 40

19.2 BTS replacement 40

19.3 PM (Personality Module) replacement 41

20 SPARE PARTS EXPLODED VIEW 42

21 SPARE PARTS 43

FAULT FINDING

22 ERROR CODES DISPLAYED 45

ELECTRICAL CIRCUITS

23 SRB & BTS Circuit Boards 47

23.1 BTS LEDs 47

23.2 BTS Terminal Locations 47

23.3 SRB LED’s 48

23.4 SRB Terminal Locations: 49

24 CIRCUIT DIAGRAMS 50

24.1 POWER CONNECTIONS e4 52

24.2 CONTROL CIRCUIT e4 53

24.3 HEATER CIRCUIT e4 54

24.4 MICROWAVE CIRCUIT e4 55

COMMISSIONING

25 Commissioning the oven 56

25.1 Initial installation 56

25.2 After Service 56

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

REGULATIONS

SAFETY &

SAFETY REQUIREMENTS1

Important:1.1

This manual provides technical guidance for engineers who have successfully undertaken a recognised product familiarisation and training course run by Merrychef to carry out service/repair tasks to the appliance/s shown on the front cover of this manual which must not be used for any other make or model of appliance.

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 or others and to protect the appliance from possible damage, ensure you have read and understand all the relevant instructions and ALWAYS follow the Safety Codes when servicing an oven.

Before attempting to repair the oven, check the oven for 1.1.1 microwave emissions using a calibrated microwave emission detector.

Check that the oven is not emitting microwaves, even 1.1.2 when supposedly not in operation.

Check that the oven is not operating continuously, 1.1.3 whether the display indicates cooking or not.

Never manipulate the mains power lead whilst it is live.1.1.4

Before removing the oven casing ALWAYS isolate the 1.1.5 oven from the mains electricity power supply; switch o and disconnect the oven plug from the wall socket, turn o isolator switch to disconnect xed wired ovens. NOTE: The oven switch does not provide adequate protection against electric shock as it does not isolate all of the internal wiring from the mains.

The equipment must be locked-o to prevent the oven 1.1.6 from being inadvertently powered up.

Do not leave the oven unattended without the oven 1.1.7 panels tted and keep within sight of other personnel when testing the oven, ensuring persons other than trained engineers are denied access.

The minimum number of panels should be removed and 1.1.8 the HT capacitors must be discharged before working on the oven using a suitably insulated 10 MΩ Resistor.

Temporary insulation should be used to prevent 1.1.9 accidental contact with dangerous conductors.

Do not touch any internal wiring within the Oven, 1.1.10 whether you believe it is live or not and avoid touching the Metalwork (Casing, Panels, etc) of the Oven with your Body.

Only use electrically rated screwdrivers for adjusting 1.1.11 ‘Pots’ etc., ensuring the tool touches nothing else.

Ensure the Test Equipment is set correctly before use.1.1.12

Test equipment such as meter test leads or clamps must 1.1.13 be tted and removed whilst the unit is dead, for each and every test.

Do not undertake functional Magnetron testing with the 1.1.14 oven panels removed.

Avoid touching the Test Equipment, unless necessary for 1.1.15 the operation.

Upon completion of a service follow the steps for 1.1.16 ‘Commissioning the oven’ under the Commissioning section of this manual.

IF SMOKE IS OBSERVED:

SWITCH OFF THE OVEN  DISCONNECT/ISOLATE FROM THE ELECTRICAL SUPPLY  KEEP THE OVEN DOOR CLOSED TO STIFLE ANY FLAMES.

DANGER:

BEFORE REMOVING THE OVEN CASING, ISOLATE THE OVEN FROM THE MAINS ELECTRICITY POWER SUPPLY; SWITCH OFF, DISCONNECT OVEN PLUG FROM WALL SOCKET, TURN OFF ISOLATOR SWITCH TO DISCONNECT FIXED WIRED OVENS AND LOCKOFF.

WARNING:

ALWAYS DISCHARGE THE HT CAPACITORS BEFORE WORKING ON THE OVEN USING A SUITABLY INSULATED 10M RESISTOR.

CAUTION

WARNING TO SERVICE TECHNICIANS PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY

Do not operate or allow the oven to be operated 1.1.17

with the door open.

Make the following safety checks on all ovens to 1.1.18 be serviced before activating the magnetron or other microwave source, and make repairs as necessary:

Interlock operation. ● Proper door closing. ● Seal and sealing surfaces (arcing, wear, and other ●

damage). Damage to or loosening of hinges and latches. ● Evidence of dropping or abuse. ●

Before turning on microwave power for any 1.1.19 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.

Any defective or misadjusted components in the 1.1.20 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.

A microwave leakage check to verify compliance 1.1.21 with the Federal Performance Standard for the U.S.A. or the Canadian Regulation, HEALTH AND WELFARE, SOR/79 920 for Canada must be performed on each oven prior to release to the owner.

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

Upper catalytic

converter

Heater elements

Convection

fan

Heater elements

Grease filter

Lower catalytic

converter

Impinger plates

PRODUCT OVERVIEW & FUNCTIONS2

CONSTRUCTION

Stainless Steel cavity and casework.

CONTROL SYSTEM

Colour touchscreen, icon driven.

Storage for up to 1024 programs with 6 stages per cooking program providing a user instruction for each stage.

USB memory stick data transfer.

Support for optional remote communications Ethernet module.

Safety system: ensures control area temperature is within limits.

MICROWAVE POWER

Two magnetrons.

Distribution system, rotating active antennae.

Microwave settings, o or 5-100% in 1% increments.

Safety system: agency approved monitored interlock door system, current monitoring and overheat detection for magnetrons.

PRODUCT

DETAILS

CONVECTED HEAT

Temperature settings 0°C o and from 100°C to 275°C in 1° C steps.

Distribution system, recalculating airow impingement.

Convection fan setting, 10-100% in 1% increments.

Safety system: oven cavity overheat detection.

Start up Sequence

With the oven switch in the OFF position and the mains power ON, the BTS & SRB boards boot up. When the oven switch is turned ON the splash screen briey displays oven information and the cabinet cooling fan is activated.

After completing a successful logic test, the safety relay is energised and the oven preheats or displays a preheat temperature choice. Once preheated the oven displays the main menu if in FS mode or a recipe selection if in QSR mode.

Shutting Down Sequence

When oven switch is turned OFF the screen displays ‘Shutting Down’ and the cooling fan operates until the cabinet temperature has been suciently reduced (cavity temperature of 50C).

The safety relay is de-energised and the BTS & SRB boards remain active.

How it works:

The convection fan pulls air in through the grease lter (1) which removes the majority of particulates from the air ow. The air is then heated and returned to the cavity through the catalysts (2) and impinger plates (3) to produce an even heat pattern in the oven. This heat layout minimises the areas where grease can build up, allowing food to cook evenly to produce a crisp golden nish.

Service & Parts Manual original Instructions

Part Number 32Z3813 US

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PRODUCT

DETAILS

MAIN FEATURES3

ON/OFF SWITCH1

ON (I) activates the oven, OFF (0) switches the oven to standby mode. IT DOES NOT ISOLATE INTERNAL WIRING FROM THE MAINS SUPPLY.

CONTROL PANEL

Touch sensitive controls (easyToUCH) for controlling oven functions, including diagnostics and service mode.

USB menuKey

A socket, located under the logo, allows a USB menuKey to be used to update the cooking programs and oven rmware on the pcb’s.

OVEN CAVITY

The oven cavity is mostly constructed from stainless steel panels which must be kept clean to avoid contamination of food products and allow the oven to perform at peak eciency.

IMPINGER PLATES (Upper & Lower)

Direct the air in the cavity. They must be cleaned on a regular basis, and kept free of debris.

OVEN DOOR

The twin-skinned door has a thermally insulated inner section to lower the surface temperature and incorporates a microwave choke.

DOOR SEAL

Provides a tight seal around the door and must be kept clean. The seal must be checked regularly and replaced if worn or damaged.

AIR FILTER

The air intake provides cooling air for internal components and must be cleaned daily and must NOT be obstructed. The lter must be in place for the oven to function.

STEAM VENT

Vents steam from the oven cavity.

HOT AIR FAN

Circulates hot air through the catalytic convertors and oven cavity.

RATING PLATE

The rating plate, located on the rear oven cover, states the Model, Serial Number, Electrical Ratings and Manufacturers telephone number.

MAINS ELECTRIC POWER CABLE

Located on the rear of the oven and must be replaced if worn or damaged.

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Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

750mm

29.5in

584mm

23.0in

591m

23.3in

643mm

25.3in 356mm

14.0in

PRODUCT

DETAILS

TECHNICAL SPECIFICATIONS4

Specications4.1

Description unit

Touch screen controls programs

Ambient operating temperature °C

External HxWxD mm

External HxWxD inches

Internal HxWxD mm

Internal HxWxD inches

Cooking chamber Ltr (cu.ins)

Power output microwave Watts

Power output convection kW

Power supply Hz

Power supply kW

Unpackaged oven weight nett Kg (lbs)

Sound pressure level dB(A)

Stacking (with kit) oven

1024

<40

591x584x750

23.3x23.0x29.5

218x375x312

8.6x14.8x12.3

25.5 (1566)

1500

3.2

50 & 60

7.0

82.5 (182)

<70

Serial Number (Rating Plate):4.2

Serial number: MM YY SITE SERIAL

i.e. 06 10 2070 12345 (1109207012345)

Oven manufactured in June 2010 at Sheeld (UK), production number 12345.

Model Number: MODEL CONVECTION MICROWAVE VOLTAGE HERTZ LEAD PLUG COMMUNICATION VERSION CUSTOMER/ACCESSORY COUNTRY

i.e. e4C S V 08 6 D F U 1 GM US (e4CSV086DFU1GMUS)

model e4C, 3200W, 1500W, 208V, 60Hz, 2P+GND (30A), moulded Hubbell plug, USB, 1, General Market, USA.

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

PRODUCT

DETAILS

INSTALLATION5

OVEN LOCATION AND POSITIONING5.1

Choose a site away from major heat sources.

DO NOT position so that hot air is drawn in from fryers, grills, griddles, etc.

A heat barrier to the height of the oven must be installed if sited next to a burner, stove or range.

Place the oven on a permanent nonslip/ nonammable at surface that is LEVEL, STABLE and STRONG enough for the oven and contents.

Allow a minimum clearance (A) of 2 inches (50mm) around the oven for hot air to escape.

Allow sucient clearance (B), in front of the oven for the door to open fully.

The air intake is located at the lower front of the oven (1) and it is important that the airow is as cool as possible and not preheated by other appliances such as burners, stoves, ranges, fryers, grills and griddles as this will deteriorate the life and performance of the oven.

Do not ax labels/stickers to oven other than those applied or approved by the manufacturer.

A A

A B

The oven will not operate without the AIR FILTER correctly tted in place.

HANDLING & STORAGE:

When moving an oven always observe and follow National and local requirements for lifting and moving heavy objects. Do not use the oven door handle to lift oven.

When not in use, electrically disconnect the oven and store safely in a dry cool place, do not stack ovens.

OVEN STACKING5.1.1

Maximum of 2 high using stacking clamps (2), part number ?????.

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

PRODUCT

DETAILS

ELECTRICAL INSTALLATION6

DANGER!

THIS APPLIANCE MUST BE EARTHED. FAILURE TO DO SO MAY RESULT IN ELECTRIC SHOCK AND DEATH.

For all cord connected appliances:

GROUNDING INSTRUCTIONS

This appliance must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. This appliance is equipped with a cord having a grounding wire with a grounding plug. The plug must be plugged into an outlet that is properly installed and grounded.

WARNING - Improper use of the grounding can result in the risk of electric shock.

Consult a qualied electrician or Serviceman if the grounding instructions are not completely understood or if doubt exists as to whether the appliance is properly grounded.

Do not use an extension cord. If the power supply cord is too short, have a qualied electrician or serviceman install an outlet near the appliance.

For a permanently connected appliance:

GROUNDING INSTRUCTIONS

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.

IN CASE OF RADIO OR TELEVISION INTERFERENCE

This equipment generates and uses radio frequency energy and if not installed and operated correctly, in strict accordance with the manufacturer’s instructions, may cause harmful interference to authorized radio communication services.

This product complies with the relevant requirements of CFR 47 Ch.1 Part 18, which are designed to provide reasonable protection against such interference. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause interference to radio or television reception, which can be determined by turning the equipment o and on, the user is encouraged to try and correct the interference by one or more of the following measures:

1) Re-orientate the receiving antenna.

2) Relocate the microwave with respect to the receiver.

3) Plug the microwave into a dierent outlet so that the receiver and microwave are on dierent branch circuits.

If necessary the user should consult the dealer or an experienced radio/television technician for additional suggestions.

Note: Modications should only be carried out by the manufacturer or authorized representative to ensure continuing conformance.

This device complies with Part 18 of the FCC rules.

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

PRODUCT

DETAILS

QUICK START GUIDE: QUICK SERVICE OVEN7

The easyToUCH screen display, layout and icons shown herein, are for guidance purposes only and are not intended to be an exact representation of those supplied with the oven.

START UP7.1

1. Switch the oven on;

Make all the relevant safety checks and ensure the oven is clean and empty before pressing the oven switch down to activate the oven.

2. The easyToUCH screen illuminates with the display briey showing the serial number and oven data. Lightly tap the screen once to freeze the display, tap again to continue.

3. When the oven is setup with two or more preheating temperatures a choice is displayed.

Scroll arrows at the bottom of the screen indicates there are more temperature choices not shown on screen, if necessary, use the scroll arrows, then select the temperature required to start preheating the oven.

4. During preheating the display shows the progress as the oven heats up to the set temperature. (To stop the oven heating touch the red ‘X’ symbol.)

5. The oven is ready to use when the ‘COOKBOOK’ is displayed.

STOP/CANCEL

COOKBOOK DISPLAY

DISPLAYS ALL COOKING PROGRAMS (Optional) SHOWS PROGRAM GROUPS FAVOURITES (Optional)

PROGRAM GROUP Each group contains a

collection of cooking programs.

CHANGE OVEN TEMPERATURE (Optional)

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

PRODUCT

DETAILS

USING A COOKING PROGRAM7.2

Taking all the necessary precautions to ensure you do not burn yourself, open the oven door to place the food into the hot oven and close the door.

1. Select a program group, for example, ‘BURGERS’ to display the individual cooking programs.

2. Select a cook program to start, for example, 2 BURGERS.

3. Follow instructions if displayed on the screen.

4. Touch the green tick to cook.

The cooking time counts down for each program stage.

5. When the program ends a red bar is displayed usually with an audible sound - open the door or touch the red ‘X’ to return to the cook program.

Note; opening the oven door during cooking stops the cooking program and displays a warning. Closing the door allows the user to continue or cancel the cooking program.

PROGRAM STAGE

AIR FILTER

IMPORTANT:

Clean the AIR FILTER (6) in the base of the oven every day and ensure that the air lter is in place prior to operating the oven. See ‘CLEANING & MAINTENANCE’.

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

PRODUCT

DETAILS

OPERATING GUIDE: FULL SERVICE OVEN8

easyToUCH MAIN MENU & 8.1

KEYBOARD SCREEN

MAIN MENU SCREEN:

1. DEVELOPMENT MODE enables multistage cooking programs to be developed, then stored under a name and symbol for reuse.

2. PRESS & GO allows quick access to use the cooking programs that are already stored.

3. COOKBOOK contains the oven’s cooking programs. It displays Favourites, Cooking Program Groups and a complete listing of all cooking programs available.

4. CLEANING/TEMP CHANGE allows the oven temperature to be changed and the oven to be prepared for cleaning with reminders displayed to assist during the cleaning process.

5. SETTINGS are used to control the oven settings and functions including time and language, loading cooking programs and for service and maintenance purposes.

6. KEYBOARD SCREEN is used to enter an authorised password to enter data for programs and may restrict operator access to some functions.

DEVELOPMENT

MODE

MENU SHORTCUT

COOKBOOK

CLEANING/ TEMP CHANGE

SETTINGS

For Program Names, Program Group Names and Passwords use 1-20 characters in 2 lines max.

For Stage instructions use 1-54 characters in 5 lines max.

KEYBOARD SCROLL

ENTER / OK

PREVIOUS SCREEN

SCREEN

CLEAR SCREEN

KEYBOARD

SPACEBAR

Backspace

RETURN

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

PRODUCT

DETAILS

DEVELOPMENT MODE: CREATING A 8.2

COOK PROGRAM

1. Select the ‘chef’s hat’ symbol from the main menu to enter development mode.

Enter stage 1 of the program

2. The temperature displays the set preheated oven temperature.

To increase or decrease the temperature required, select the temperature symbol (2), enter the temperature in the keypad within the limits displayed and select OK.

3. Select and set the cooking time up to a maximum of 10 minutes.

For example : Enter 110 (1minute and 10 seconds).

4. Select and set the Microwave Power [0, 5-100%]

5. Select and set a Fan speed (if available) within the limits shown.

6. Select the information icon to enter an instruction (Optional). The instruction appears in the display at the beginning of that stage.

For example : ‘Stage 1 place product in the oven’.

Example below; setting the cooking time (step 3): To Set the cooking Time

select the Time symbol.

Enter the cooking time on the pad.

CLEAR

Select OK to accept the time.

Enter stage 2 of the program (Optional).

7. Programs can have up to a maximum of 6 stages.

Repeat the steps 2-6 from stage 1 above.

Running and saving the program

1. Select OK to conrm the Program.

WARNING: ENSURE PRODUCT IS IN THE OVEN AND ALL SAFETY PRECAUTIONS ARE FOLLOWED BEFORE RUNNING THE PROGRAM.

2. Run the program (optional).

If the results are not satisfactory, select the backspace, change the cooking settings and retest.

3. Select the save Cookbook symbol to record the program to the cookbook.

4. Select an image to represent the program.

(Use the scroll arrows for more pictures.)

5. Enter the name for the cooking program, using a maximum of 20 characters, for example, ‘1 BURGER’, then select OK to save the program to the Cookbook.

6. A symbol with a green tick on a book is displayed to indicate that the program has been successfully saved to the Cookbook.

STAGE 1 DISPLAYED

ADD STAGE

DELETE STAGE

STAGE 2 DISPLAYED

BACK TO STAGE 1

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

PRODUCT

DETAILS

PRESS & GO8.3

Running a cooking program from the Press & Go menu.

1. Select ‘PRESS & GO’ from the main menu screen.

2. Select the item required to cook.

3. The display shows the temperature, cooking time, microwave power and fan speed while the timer counts down. The timer bar turns red to indicate the cooking cycle has nished.

Choosing which cooking programs are shown in the ‘PRESS & GO’ menu screen.

1. After selecting ‘PRESS & GO’ from the main menu screen, select the EDIT symbol.

2. Two lists are displayed, the ‘PRESS & GO’ menu items are shown in the upper list and the lower list shows other menu items which are available. Both lists can be scrolled up or down using the arrows on the extreme right.

3. Select an item, then choose whether to change its order within the menu or to remove it into the lower list.

4. Select an item to move into the upper list, making it available in the ‘PRESS & GO’ menu.

5. Select backspace to return to the menu screen when nished.

Change the order of a selected item shown in the Press & Go screen.

Move a selected item to or from the Press & Go screen.

Select to scroll a list up or down.

USING A COOKBOOK PROGRAM8.4

To nd the required Program in the cookbook.

WARNING: ENSURE THERE IS FOOD PRODUCT IN THE OVEN BEFORE STARTING A COOKING PROGRAM.

1. Select ‘COOKBOOK’ from the main menu screen.

2. Select the ALL MENUS symbol.

3. Use scroll up/down arrows to nd the program.

NOTE: if an image has a red line around it the oven temperature is set too high or too low for that recipe. See ‘CHANGING THE OVEN TEMPERATURE’.

Taking all the necessary precautions to ensure you do not burn yourself, place the food product into the hot oven cavity and close the door.

WARNING: HOT SURFACE HAZARD

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Service & Parts Manual original Instructions

Part Number 32Z3813 US

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PRODUCT

DETAILS

4. Select the required cooking program to start cooking.

For example, ‘1 BURGER’.

5. The program either starts immediately displaying a countdown timer, or an instruction is displayed rst; follow the stage instruction then select OK to start cooking. If the oven door is not opened within 30 seconds a warning message appears.

6. The cooking timer counts down to zero and makes a sound to indicate an operator action is required at the end of a cooking stage or the end of a cooking program.

Once the cooking program has nished, opening the oven door to remove the food returns the display to the ‘COOKBOOK’ screen.

Note; opening the oven door during cooking stops the cooking program and displays a warning. Closing the door allows the user to continue or cancel the cooking program.

To check the oven temperature when cooking, lightly tap the temperature displayed, the oven cavity temperature is shown with an asterisk.

5 64

CHANGING THE OVEN 8.5

TEMPERATURE

1. Take note of the temperature required for the recipe and select OK.

2. Select the temperature symbol.

3. An asterisk next to the number indicates the present oven temperature, select the required oven temperature for the recipe. Once the oven is at the required temperature continue from selecting the ‘COOKBOOK’ in step 1.

VIEWING & EDITING PROGRAMS8.6

1. Select ‘COOKBOOK’ from the main menu screen.

2. Select the ALL MENUS symbol.

3. Select ‘EDIT COOKBOOK’.

4. Use the up/down scroll arrows on the right side of the screen to nd the cooking program, for example 1 BURGER and select the view/edit cooking program symbol.

5. View or adjust the program as required, see Development mode for details.

1 2 3

4 5

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

PRODUCT

DETAILS

ADDING A NEW PROGRAM GROUP8.7

To add a new Program Group.

1. Select ‘COOKBOOK’ from the main menu screen.

2. Select ‘EDIT COOKBOOK’.

3. Select the ‘ADD A NEW GROUP’ symbol.

4. Enter a name for the new Program Group (max. 20 characters).

5. Select an image to represent the Group.

(Use the scroll arrows for more pictures.)

6. Select OK to save the Program Group to the Cookbook.

Select backspace to return to the ‘COOKBOOK’.

MOVE A PROGRAM WITHIN A 8.8

PROGRAM GROUP

Example moving the position of the ‘4 BURGERS’ cooking program within the program group called ‘BURGERS’.

1. Select ‘COOKBOOK’ from the main menu screen.

2. Select the ‘BURGERS’ program group.

3. Select ‘EDIT COOKBOOK’.

4. Use the up/down scroll arrows on the right side of the upper part of the edit screen to view the cooking programs in the group.

Then select the cooking program to be moved (‘4 BURGERS’) and use the up/down arrows on the left side of the upper screen to move the selected program within the program group.

Select backspace to return to the ‘COOKBOOK’ screen.

1 2 3

Program Group

Move the selected program within the Program Group

Scroll to show programs in the current Program Group

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

PRODUCT

DETAILS

ADDING A PROGRAM TO A GROUP8.9

To add a cooking program to an existing PROGRAM GROUP.

Example add Program ‘4 BURGERS’ to the program group ‘BURGERS’.

1. Select ‘COOKBOOK’ from the main menu screen.

2. Select the ‘BURGERS’ Program Group.

3. Select ‘EDIT COOKBOOK’.

4. In the lower part of the screen use the up/down scroll arrows on the right side to nd and select the ‘4 BURGERS’ cooking program.

5. Select the green UP arrow to add the ‘4 BURGERS’ cooking program to the Program Group in the upper part of the screen, then select backspace to return to the cooking programs.

6. Select backspace again to return to the ‘COOKBOOK’.

MANAGING PROGRAM GROUPS8.10

To move a program position in a Program Group

1. Select ‘COOKBOOK’ from the main menu screen.

2. Select ‘EDIT COOKBOOK’.

3. Use the scroll arrows, up and down on the right side of the screen to locate all the Program Groups.

4. Select the Program Group to be moved and use the up and down arrows, on the left side of the screen to move the selected program.

5. Select backspace to go back to the ‘COOKBOOK’.

To change the Program Group name.

Select the Program Group.

Select EDIT PROGRAM GROUP.

Enter the new name and select OK.

To delete a Program Group

Select the Program Group.

Select the DELETE Program Group symbol.

Select OK to Delete the Group.

Move the selected Program Group

Edit the selected Program Group name

Scroll to show

Program Groups

Delete the selected Program Group

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

PRODUCT

DETAILS

OVEN CONTROL SETTINGS9

1. Select the ‘settings’ symbol from the main menu screen.

2. Enter the password and select OK to display the Settings menu (3) comprising:

A. Oven mode/navigation settings.

B. Language options.

C. Oven temperature settings and labels.

D. Service information and error logs (password required).

E. Recipe counters.

F. Date & time settings.

G. Speaker sound levels.

H. Oven Timer (Temperature/ON/OFF).

J. USB program connection.

K. Restore settings to Factory defaults.

L. Temperature Band.

M. Change Settings/Service access passwords.

When nished with a setting, select backspace to return to the main settings menu.

To exit the settings menu, select backspace, a prompt will be displayed to either ‘SAVE’ or ‘DISCARD’ any changed settings (4).

1 2

3 4

A B

Oven mode/navigation settings (A)9.1

Select the oven mode/navigation symbol (A) 9.1.1

from the ‘Settings’ menu.

Select ‘Quick Serve Mode’ for cooking only, 9.1.2 or ‘Full Serve Mode’ for cooking & development programs.

Select ‘Enable Settings’ to display an ‘unlock’ 9.1.3 symbol on the Quick Serve Cookbook screen to allow access to the ‘Settings’ menu.

Language options (B)9.2

Select the globe symbol (B).9.2.1

Select the checkbox of the required language 9.2.2 from the list shown.

Oven temperature settings and 9.3

labels (C)

To change the oven preheat temperature, select 9.3.1 the temperature symbol (C) to display the keypad, enter the required temperature and select OK.

Note, the temperature options screen is only 9.3.2 displayed at start up when two or more temperatures are set above minimum.

To change a temperature label, select the label 9.3.3 to display the keyboard, enter the required label name and select OK.

For Service information & error logs (D) refer to Servicing.

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

PRODUCT

DETAILS

Recipe counters (E)9.4

Select the clipboard symbol to display a listing of 9.4.1

recipe counters.

If shown, use the arrows (bottom right) to scroll 9.4.2

up and down the list.

Date and Time settings (F)9.5

Select the time/date symbol to display the 9.5.1

setting options.

CHANGE THE DATE: Select ‘MONTH’, enter the 9.5.2

correct Month on the keypad and select OK.

Select ‘DAY’, enter the correct Day on the keypad 9.5.3

and select OK.

Select ‘YEAR’, enter the correct last two digits of 9.5.4

the Year on the keypad and select OK.

To display the Month rst, followed by the Day 9.5.5 and Year, select the ‘MM-DD-YY’ checkbox. Note; the Error Logs are recorded using these settings.

CHANGE THE TIME: Select ‘HOUR’, enter the 9.5.6 correct Hour on the keypad and select OK.

Select ‘MIN’, enter the correct Minutes on the 9.5.7 keypad and select OK.

Select the ‘AM’ or ‘PM’ checkbox for a 12 Hour 9.5.8 clock or select ‘24’ for a 24 Hour clock.

Select the day name shown to cycle through to 9.5.9 display the correct weekday.

Sound levels (G)9.6

Select the speaker symbol to display the volume 9.6.1 levels.

Select a sound level suitable for the environment 9.6.2 from none (OFF) to the loudest (100%).

Oven Timer (H)9.7

Select the thermometer/timer symbol.9.7.1

Select the ‘Timer Enabled’ checkbox (green tick).9.7.2

Select a weekday using the up/down arrows.9.7.3

Select an empty ‘Time’ box (maximum of 5 per 9.7.4 day) or clear the box using the wipe symbol.

Enter the start time on the keypad and select OK.9.7.5

Select an empty ‘Temperature’ box opposite the 9.7.6 Time box displaying the time just entered, or clear the box using the wipe symbol next to it.

Enter the cavity temperature required on the 9.7.7 keypad and select OK. Note; you can also select zero to turn the heat o. Selecting the red circle symbol will switch the oven OFF.

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

PRODUCT

DETAILS

USB oven programs (J)9.8

IMPORTANT: Downloading from a USB will clear all the existing programs.

Check that the key has the correct number/code for the programs you want to load into the oven memory.

Select USB from the settings screen.9.8.1 Slide the USB cover (logo on the oven front) 9.8.2

upwards to insert the USB into the slot.

When the inserted USB stick has nished 9.8.3 ashing, select the required USB symbol, for example; RECIPES.

Select the new le using the scroll arrows if 9.8.4 required to locate the le. Note; a tinted band over a le name indicates the le is not available to use.

Double check the le is correct before selecting 9.8.5 OK, if not, select ‘X’ and locate the correct le.

Progress of the le update is displayed. Once 9.8.6 completed the oven restarts and commences heating up to the PREHEAT temperature ready to cook.

Remove the USB and keep in a safe place. 9.8.7 Reposition the USB cover.

Restore Factory Defaults (K)9.9

Select the factory symbol to replace the existing 9.9.1 oven settings with the original factory default settings. Note; this action cannot be undone.

Select OK, or select the red cross to cancel and 9.9.2 keep the existing settings.

Temperature Band (L)9.10

Select the ‘Temp Band’ symbol at which the 9.10.1

oven controls i.e. ±10°C.

Select the required temperature band 9.10.2 checkbox, shown by a green tick. Note; although the lowest practical Temp Band should be used, if the set oven temperature falls by more than the selected Temp Band, the ready to cook mode and Temp Band are deactivated until the oven reaches the preheat temperature.

Change Password (M)9.11

Select the key symbol to change the oven 9.11.1 passwords.

Select the oven Settings or Service symbol.9.11.2

Enter the existing password and select OK to 9.11.3 conrm.

Enter the new password, select OK.9.11.4

Conrm new password, select OK.9.11.5

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

PRODUCT

DETAILS

COOLING THE OVEN DOWN BEFORE CLEANING10

Oven cool down10.1

IMPORTANT: the oven must be cooled down before the cleaning processes are carried out.

1. In Full Serve mode, select the CLEANING symbol from the main menu.

2. In Full or Quick Serve mode, select the blue thermometer symbol to disable heating and start the cooling cycle.

3. Taking all necessary precautions place a suitable heaped container of ice, into the hot oven cavity. Select the OK symbol to continue.

4. The cooling progress is displayed and takes approximately 30 minutes.

5. The oven is now ready for cleaning. Select OK on the screen after completing each stage.

Preparing to clean the oven10.2

For the oven to operate at peak eciency, the cavity, door, air lter and grease lter must be kept clean.

A daily cleaning routine will ensure that you comply with the required hygiene standards and will help to maintain and prolong the eciency of your oven.

Equipment required (not supplied):

Non-caustic proprietary branded oven cleaner, heat proof gloves, protective rubber gloves, non– abrasive nylon scrub pad, cleaning towel and cloths, eye protection and dust mask (optional).

CAUTION: WEAR PROTECTIVE RUBBER GLOVES WHEN CLEANING THE OVEN.

NEVER use sharp implements or harsh abrasives on any part of the oven.

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

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

Cold oven CLEANING INSTRUCTIONS e411

PRODUCT

DETAILS

Complete COOL DOWN procedure and allow the oven and accessories to cool before commencing cleaning.

DO NOT USE TOOLS

REMOVE & CLEAN Oven Parts:

1. Remove the air lter at the base of the oven.

2. Open the oven door, remove the rack, pull the grease lter handle downwards and lift out.

3. Undo the fasteners securing the top impinger plate.

4. Remove top impinger plate and lift out bottom impinger plate.

Wash all parts in warm soapy water. Wash o using a clean cloth and plenty of clean, warm water.

Dry using a fresh, clean cloth.

CLEAN THE OVEN:

1. Remove any spillages with disposable paper wipes.

Use a dry clean brush to remove any food particles from between the oven oor and the inside of the front door.

2. Wear protective rubber gloves and protective glasses, carefully spray a non-caustic proprietary branded Oven Cleaner onto all the internal surfaces of the oven except the door seal (A).

DO NOT spray directly into the fan opening at the rear inside of the oven.

3. For dicult areas, leave to soak for 10 minutes with the oven door open.

Use a non–abrasive nylon scrub pad/sponge to clean the cavity, roof and the inside of the door. Do not scrub the door seal or use metallic scourers.

4. Wash o using a clean cloth and plenty of clean warm water and dry using a fresh clean cloth or paper towel.

Replace all the cleaned oven parts.

Close the oven door and wipe the outside of the oven with a damp cloth.

1 2

DO NOT USE THE OVEN WITHOUT A CLEAN AIR FILTER IN PLACE

APPLY OVEN PROTECTOR:

1. Only apply to a clean oven. Spray proprietary branded Oven Protector onto a sponge.

2. Spread Oven Protector lightly onto all internal surfaces of the oven.

3. Spread Oven Protector lightly onto the internal surface of the oven door avoiding the door seal.

Switch on the oven and preheat. When the oven has reached operating temperature it will take about 30mins to cure the Oven Protector.

Note: Oven protector turns light brown when cured.

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

SERVICING THE OVEN12

Servicing Procedure:12.1

Disconnect/isolate the oven from the power 12.1.1

supply.

Check the oven is correctly installed as described 12.1.2 in the Installation Instructions (Product Details section).

Visually check the cleanliness/condition of 12.1.3 the power supply/cable/gland, oven casing, cavity and door for signs of wear, damage, distortion etc., if required, refer to the ‘Spares & Replacement’ section.

Complete an ‘Earth/Insulation test’ (Testing 12.1.4 Components section) on the oven before switching on.

Check the display for Error messages, if an Error 12.1.5 is shown, refer to ‘Errors & Diagnostics’ (Servicing section).

Note; If a Firmware update is required, follow 12.1.6 the instructions under ‘Firmware Updates’ (Servicing section) before continuing with the service procedure.

Enter Service mode:12.2

On start up, tap the top right of the main menu 1 screen to bypass oven preheat.

Enter the authorised user password, for

example, MANAGER and select OK to display the Settings menu.

Select the spanner symbol.

Enter the service password, for example SERVICE 4 on the keyboard and select OK to display the error log, service information and test options.

Check the Error Log for details of any logged 12.2.1 oven errors. See ‘Errors & Diagnostics’ (Servicing section) for more details.

Check the ‘Oven Counters’ to nd the usage of 12.2.2 components and the Controls area temperature within the cabinet. (‘Errors & Diagnostics’, Servicing section).

Check the operational performance of the main 12.2.3 components using the Visual or Data View (‘Errors & Diagnostics’, Servicing section).

Perform the Oven tests, (Testing Components 12.2.4 section). If required refer to the ‘Spares and Replacement’ section for any repairs needed before continuing with the Oven Tests.

Follow the procedures under the 12.2.5 ‘Commissioning’ section before commissioning the oven for use.

DANGER:

WARNING:

ALLOW OVEN TO COOL AND OBSERVE AND FOLLOW ALL SAFETY PRECAUTIONS INCLUDING THOSE DESCRIBED UNDER THE SAFETY REGULATIONS SECTION OF THIS MANUAL BEFORE ATTEMPTING A SERVICE OR REPAIR.

CAUTION MICROWAVE EMISSIONS:

DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY.

SERVICING

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Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

SERVICING

ERRORS & DIAGNOSTICS13

ERROR MESSAGES13.1

A description of the type of error is shown. 13.1.1 Check for a number following ‘ERROR:’ (A) and refer to the Error Codes (Fault Finding section) for more details. The Oven Serial Number, Model, UI (BTS) version and SRB version information is also displayed below.

Clear the Error message by power cycling the 13.1.2 mains power supply to the oven (not the oven ON/ OFF switch).

COPYING ERROR MESSAGES:13.2

Enter oven settings menu (B) and select the 13.2.1 USB symbol.

Slide up the USB cover and insert the USB 13.2.2 memory stick.

Select Upload Files.13.2.3

Select Error Log.13.2.4

Select OK to copy the Error Log to the USB 13.2.5 memory stick. The upload progress is shown followed by the upload status.

Select backspace 3 times to return to the main 13.2.6 menu.

Remove the USB memory stick and replace the 13.2.7 USB cover.

ERROR LOG13.3

Enter Service Mode and select ‘ERROR LOG’ (C) 13.3.1 to display a listing of oven component errors. Error details include; component description, error caused, Date & Time of the Error with details of Failure and Range.

Scroll down the list (if necessary) and select an 13.3.2 error from the list to display individual records.

Select backspace to return to the list, again to 13.3.3 return to the Service menu.

OVEN COUNTERS13.4

Select ‘OVEN COUNTERS’ (D) to display the 13.4.1 oven component usage and ambient Controls area temperature. Details include the number of screen touches, lter cycles, door cycles, total Oven, Magnetron and Heater element power on time and the ambient controls area temperature in the cabinet.

Select backspace to return to the Service menu.13.4.2

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

SERVICING

VISUAL VIEW13.5

Select VISUAL VIEW (E) to check the main oven 13.5.1 components. Select a component symbol to switch on (red), select again to increase the level or turn o (green).

Remove the front air intake lter, the colour 13.5.2 should change from green to red on the display indicating that the magnetic reed switch circuit for the air intake lter is operating. Replace the lter and the colour should change back to green.

Open the oven door and check the colour 13.5.3 changes from green to red on the display to check the door microswitch/interlock circuit is operating. Place door spacers onto the oven door (refer to Door Interlock Adjustment (Testing Components section) for details), close the door and check the colour on the display. Green indicates the door adjustment is ok, red indicates that the Door Interlock Adjustment procedure must be completed.

Select the cooling fan and check it’s operating 13.5.4 correctly.

Place a microwave safe container of water into 13.5.5 the oven, close the oven door and select a magnetron to test the current draw at maximum output, this will time-out after 30 seconds. For dual magnetron models, test the magnetrons individually and together. Using heat proof gloves, remove the container and close the oven door.

Select the Convection Fan and check it is 13.5.6 operating correctly.

Select the Heating Element, it increases to 13.5.7 maximum temperature then cycles (the Convection Fan is on by default). Check the cavity temperature and heater element current draw at maximum are correct.

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

SERVICING

FIRMWARE UPDATES14

Note: if icons are not displayed on the screen, press in the same positions on screen as the missing icons to select.

Tap the top right of the screen (1) or the same 14.5.1

position if it is not displayed to bypass oven preheat.

Enter a password (i.e. “Manager”) and select OK 14.5.2 (2) or the same position if the green tick symbol is not displayed.

Select the USB symbol (3) or the same position 14.5.3 if it is not displayed.

Select one of the USB options (4) or the same 14.5.4 position if it is not displayed: ‘Firmware’ for BTS & SRB updates and ‘Recipe’ for Icons. Install the SRB update rst, the BTS update second and Icons third.

Select the rmware to install and select OK (5) 14.5.5 to conrm or the same position for the OK (green tick symbol), if it is not displayed.

The update screen displays the le version 14.5.6 and product, select OK (green tick symbol) to conrm installation (6) or the same position if it is not displayed.

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Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

SERVICING

IMPORTANT:

Downloading from a USB will clear all existing programs. Update the ‘SRB’ rst, the ‘BTS’ second and the ‘Icons’ third (found under the USB ‘Recipe’ heading).

Switch on the oven and tap the top right of the 14.5.7

screen (1) to bypass the preheat stage.

Enter the password and select OK to display the 14.5.8

Settings menu, see (2).

Select the USB symbol (4).14.5.9

Slide the Merrychef badge (oven front top 14.5.10 right) upwards and insert the USB Memory Stick into the slot (3).

DO NOT REMOVE USB DURING DOWNLOAD SEQUENCE AS THIS COULD CORRUPT THE USB DATA.

1 2

Once the USB has stopped ashing, select the 14.5.11 ‘FIRMWARE’ USB symbol (5).

The current BTS (Touch Screen) & SRB (Smart 14.5.12 Relay Board) Firmware versions are displayed at the top left of the screen (6).

SRB FIRMWARE UPDATE

Select the ‘SRB’ le required (7).14.5.13

Check the le information is correct before 14.5.14 selecting OK (8).

Update progress is displayed (9).14.5.15

Select backspace (10) 3x to return to the USB 14.5.16 screen shown (11).

If the rmware versions are far apart an SRB 14.5.17 conict could cause an error message (12) to be displayed.

BTS FIRMWARE UPDATE

Select the ‘BTS’ le (13) with the correct le 14.5.18 version number. Note; a tinted band over a le name indicates the le is not valid for that oven.

Check the le information shown is correct 14.5.19 before selecting OK (14), if not, select ‘X’ and locate the correct le.

The le update progress is displayed (15). 14.5.20 At 50% the cooling fan stops operating, after 100% various screen displays appear as the software reboots.

Check the screen shows the correct BTS 14.5.21 version was installed (16), if not, repeat the process using the correct le.

Remove the USB and keep in a safe place. 14.5.22 Reposition the USB cover.

11 12

14 15

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

OVEN TESTING15

Equipment required15.1

Portable Appliance Tester (P.A.T.). ● Digital Multi-meter (D.M.M.). ● Megger / similar 500V d.c. resistance meter. ● Microwave detection / leakage meter. ● Temperature reader. ● Continuity meter. ● Door Spacer Kit (Part No. SA1109). ● Microwave safe 600ml glass beaker ● Microwave safe 2 litre container. ●

DANGER!

THIS APPLIANCE MUST BE EARTHED. FAILURE TO DO SO MAY RESULT IN ELECTRIC SHOCK AND DEATH.

DANGER:

BEFORE REMOVING THE OVEN CASING, ISOLATE THE OVEN FROM THE MAINS ELECTRICITY POWER SUPPLY;

SWITCH OFF, DISCONNECT OVEN PLUG FROM WALL SOCKET, TURN OFF ISOLATOR SWITCH TO DISCONNECT FIXED WIRED OVENS AND LOCKOFF.

WARNING:

ALWAYS DISCHARGE THE HT CAPACITORS BEFORE

WORKING ON THE OVEN USING A SUITABLY INSULATED 10M RESISTOR.

WARNING:

ALLOW OVEN TO COOL AND OBSERVE AND FOLLOW ALL

SAFETY PRECAUTIONS INCLUDING THOSE DESCRIBED

UNDER THE SAFETY REGULATIONS SECTION OF THIS

MANUAL BEFORE ATTEMPTING A SERVICE OR REPAIR.

CAUTION MICROWAVE EMISSIONS:

DO NOT BECOME EXPOSED TO EMISSIONS FROM THE

MICROWAVE GENERATOR OR PARTS CONDUCTING

MICROWAVE ENERGY.

Earth/Insulation Test:15.2

Disconnect/isolate the oven from the power 15.2.1

supply.

Connect the mains lead from the oven to a P.A.T. 15.2.2

(Portable Application Tester).

Connect the Earth from the P.A.T. to the oven 15.2.3

hinge (A).

Place the P.A.T. in an open area, such as the oor, 15.2.4

away from any persons.

Perform a Class 1 test, a PASS indicates the oven 15.2.5

Earthing circuit is functioning ok.

If a FAIL is indicated, remove the oven casing and 15.2.6

check ALL earth connections before retesting.

NEVER operate an oven that has failed this test 15.2.7

as it could be potentially dangerous.

Screen calibration:15.3

Apply continuous light pressure to the top 15.3.1

right of the screen while switching the oven on.

Using a non-abrasive pointer, such as a 15.3.2 ball point pen, accurately press the center of each crosshair displayed on the screen. Once calibrated the screen will display the oven information.

TESTING

COMPONENTS

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

TESTING

COMPONENTS

OVEN TESTS15.4

Enter Service mode (Servicing section).15.4.1 Select the down arrow to display the individual 15.4.2

Oven tests (A) for the oven to perform.

Microwave Power Test15.5

Measuring the power output.

Note: The power output is established under IEC 705 standard method which is only workable in Laboratory controlled conditions. Power output is also aected by line voltage under load, so this test is an approximation only.

Ensure the oven is cold, then enter Service mode 15.5.1

to bypass oven preheating.

Select Visual View (B) to check the oven cavity 15.5.2

temperature reading is as close to 0°C as possible.

Fill a microwave safe container (glass or plastic)

with one litre (1.78 pints) of tap water at about 20°C (68°F).

Measure and record the water temperature in

the container using a thermometer capable of reading ±0.1 degree increments.

Place the container centrally inside the oven.

Select ‘Microwave Power Test’ (C) from the 4 service mode tests. (Microwave power 100% for 63 seconds, fan minimum).

When the countdown has nished, remove the

container from the oven, immediately stir with a plastic implement and measure the water temperature.

Calculate the temperature rise of the water (end

temperature minus the start temperature).

The Temperature Rise should be:

21.5°C (71°F) ±5%

If the temperature rise is outside these limits:

Check the microwave circuit and components, ● (Testing Components section).

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

TESTING

COMPONENTS

Microwave Leakage Test15.6

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 deection, ● 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 at 2.5cm/second.

Always hold the probe at right angles to the ● oven and point of measurement, ensuring the probe is reading 50mm from the test area.

With any casework removed the leakage should ● not exceed 5mW/cm².

Procedure

Add 275ml of cold water into a 600ml 15.6.1 microwave safe container.

Place the 600ml container in the centre of oven 15.6.2 and close the door.

Enter Service mode and select ‘Microwave 15.6.3 leakage test’ (A) from the oven tests.

Set the leakage meter to the appropriate scale/15.6.4 range.

Move the survey meter probe across all 15.6.5 casework joins and vent areas including those marked in yellow, shown opposite.

When the Magnetron circuit stops after 30 15.6.6 seconds, change the water and re-select the test to continue.

Select the red ‘X’ on the display to stop the test 15.6.7 at any time.

Readings must be below 5mW/cm². If a level 15.6.8 greater than 5mW/cm² is observed, this should be reported to Merrychef Service Department immediately.

Notes should be kept of any leakage that is 15.6.9 observed in terms of the level and position on the oven. This information should be kept with the service documentation.

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

TESTING

COMPONENTS

Temperature Control Test15.7

Measuring the oven cavity temperature.

(Note; re-calibrating the Thermocouple with the SRB is normally only required when the Thermocouple has been replaced or the oven is under or over cooking.)

Procedure:

Place the probe of a temperature reader (A) 15.7.1 onto a heat sink in the centre of the oven cavity and close the oven door.

Select ‘Temperature Control Test’ (B) from the 15.7.2 service mode tests. The oven heats up and cycles at the maximum set point temperature over 30 minutes.

Once the oven is up to maximum temperature 15.7.3 check for a stable temperature reading.

Select the red X to nish the test, if necessary.15.7.4

If the temperature reading is dierent to the 15.7.5 maximum set point, scroll up (C) to select TEMP. COMP. (Temperature Compensation) (D) and enter the password.

Enter the gure from the temperature reader 15.7.6 on the keypad (E) and select OK to calibrate the SRB to the thermocouple.

Retest to check that the oven cavity 15.7.7 temperature reading is the same as the oven maximum set point temperature.

If the temperature reading is unstable:

Disconnect and isolate the oven from the

electricity supply.

Allow the oven to cool down.

Remove the oven casing.3 Check the cavity temperature sensor wire and 4

connections.

If the wire and connections are ok; replace

the cavity temperature sensor (see Spares & Replacement section).

Replace oven casing, switch ON and retest.

If the temperature is still unstable repeat steps 1 7 to 3, replace the SRB (see Spares & Replacement section), repeat step 6. NOTE: reuse the existing PM (Personality Module) on the new SRB (enter Serial No. on reboot).

Repeat the Temperature Control Test 15.7.8 procedure.

A B

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

TESTING

COMPONENTS

Soak Test15.8

Checking the oven cavity integrity.

Procedure:

Place an oven/microwave safe container with 15.8.1

approx. 2 litres of water into the oven.

Close the oven door and select ‘Soak Test’ (A) 15.8.2 from the Service mode oven tests (maximum oven temperature, 50% microwave power, maximum fan speed).

Run the test (30 minutes), carefully checking the 15.8.3 oven casing, joints and door seal for signs of steam or water escaping from the oven cavity.

If necessary, rectify any leaks and repeat the test.15.8.4

Safely remove the container from the oven.15.8.5

Recommission Test15.9

The Recommission tests are performed following the completion of a service or repair to ensure the oven is operational before handing back to the customer.

Some of the tests have a countdown timer where failing to carry out a test within the time limit will cause a test failure and the Recommission test will have to be restarted.

Procedure:

Select ‘Recommission Test’ (A) from the service 15.9.1 mode oven tests and follow the on screen instructions to perform the tests. Do not select the red ‘X’unless you want to stop the test.

After a test has successfully passed, select OK to 15.9.2 continue.

When all the tests have been successfully 15.9.3 performed the display shows the Recommission test has passed, select OK to conrm.

In the event of a Recommission test failure, 15.9.4 the detail will be recorded in the Error log. Any error should be rectied and the Recommission test run again.

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

TESTING

COMPONENTS

HIGH VOLTAGE COMPONENTS16

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 lament.

Even when the oven is not cooking, the High Voltage Capacitor has High Voltages present because of the Soft Start circuit.

Power Transformer Test16.1

Disconnect and isolate the oven from the 16.1.1

electricity supply.

Allow the oven to cool down.16.1.2 Remove the oven casing.16.1.3 Ensure that the High Voltage Capacitor is 16.1.4

discharged before commencing work.

Remove all connections from the Power 16.1.5

Transformer.

Using a D.M.M., check the resistance of the 16.1.6

windings. Results should be as follows:

Mains winding between tags, approx. 1.1 Ω

High Voltage winding, approx. 60 Ω2 Filament winding between terminals, less than 3

1 Ω

Using a Megger, test the insulation resistance 16.1.7

between:

Primary winding and chassis, pass if reading is ● over 10 MΩ

Filament winding and chassis, pass if reading is ● over 10 MΩ

One end of the High Voltage winding is connected to the chassis, so this is not tested.

DANGER:

BEFORE REMOVING THE OVEN CASING, ISOLATE THE OVEN FROM THE MAINS ELECTRICITY POWER SUPPLY;

SWITCH OFF, DISCONNECT OVEN PLUG FROM WALL SOCKET, TURN OFF ISOLATOR SWITCH TO DISCONNECT FIXED WIRED OVENS AND LOCKOFF.

WARNING:

ALWAYS DISCHARGE THE HT CAPACITORS BEFORE

WORKING ON THE OVEN USING A SUITABLY INSULATED 10M RESISTOR.

WARNING:

ALLOW OVEN TO COOL AND OBSERVE AND FOLLOW ALL

SAFETY PRECAUTIONS INCLUDING THOSE DESCRIBED

UNDER THE SAFETY REGULATIONS SECTION OF THIS

MANUAL BEFORE ATTEMPTING A SERVICE OR REPAIR.

CAUTION MICROWAVE EMISSIONS:

DO NOT BECOME EXPOSED TO EMISSIONS FROM THE

MICROWAVE GENERATOR OR PARTS CONDUCTING

MICROWAVE ENERGY.

High Voltage Rectier Test (Diode 16.2

Board)

Disconnect and isolate the oven from the 16.2.1

electricity supply.

Allow the oven to cool down.16.2.2 Remove the oven casing.16.2.3 Ensure that the High Voltage Capacitor is 16.2.4

discharged before commencing work.

Remove all connections from the High Voltage 16.2.5

Rectier.

Using a Megger, test for continuity in both 16.2.6

directions. Results should be as follows:

Open circuit both ways - FAIL ● Conducts one-way only - PASS ● Short circuit both ways - FAIL ● Conducts one way, leaks the other - FAIL ●

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

TESTING

COMPONENTS

Even when the oven is not cooking, the High Voltage Capacitor has High Voltages present because of the Soft Start circuit.

High Voltage Capacitor Test16.3

Disconnect and isolate the oven from the 16.3.1

electricity supply.

Allow the oven to cool down.16.3.2 Remove the oven casing.16.3.3 Ensure that the High Voltage Capacitor is 16.3.4

discharged before commencing work.

Remove all connections from the High Voltage 16.3.5

Capacitor.

Using a D.M.M., check for continuity between 16.3.6

the terminals. Results should be as follows:

Between Terminals, pass if approx. 10 MΩ

Between Terminals and case, pass if open circuit.2

Using a Megger, test the insulation resistance 16.3.7 between the Terminals and case, pass if reading is over 100 MΩ

High Voltage Magnetron Test16.4

Disconnect and isolate the oven from the 16.4.1 electricity supply.

Allow the oven to cool down.16.4.2

Remove the oven casing.16.4.3

Ensure that the High Voltage Capacitor is 16.4.4 discharged before commencing work.

Remove all connections from the High Voltage 16.4.5 Magnetron.

Using a Megger check for continuity. Results 16.4.6 should be as follows:

Filament terminals, pass if 1 Ω or less.

Between each lament terminal and the metal 2 outer case should read open.

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

SW1

SW2

SW3

SW1

SW2

TESTING

COMPONENTS

MAINS VOLTAGE COMPONENTS17

Door Interlock Adjustment17.1

Located on the door hinges are 3 safety interlock microswitches, to prevent microwave emissions escaping when the oven door is opened:

The Primary (SW3) breaks the electrical supply circuit to the transformers.

The Secondary (SW2) breaks the microwave circuit if the primary fails.

The Monitor switch (SW1) will short out the Microwave circuit blowing the fuse if both Primary and Secondary interlocks fail.

IMPORTANT: in the event that the Monitor switch causes the Microwave circuit fuse to blow, the Secondary (SW2) and Monitor (SW1) microswitches must be replaced due to exposure from high short-circuit currents.

The purpose of the following adjustment procedure is to set the interlock to switch o the Microwave circuit when the door is opened more than 4mm and for the Microwave circuit to operate when the door is closed and the door seal expands.

Door Interlock Adjustment procedure:17.1.1

Disconnect and isolate the oven from the 17.1.2

electricity supply.

Allow the oven to cool down.17.1.3 Remove the oven casing.17.1.4 Ensure that the High Voltage Capacitor is 17.1.5

discharged before commencing work.

Position red 2mm spacers over the top corners

of the door seal and carefully close the door ensuring the spacer is still in position.

Slacken the pivot screw.

Release the adjusting screws and move the 3 backplate until microswitch SW3 just activates then secure all screws.

Open door to replace the red 2mm spacers with

green 4mm spacers and close the door.

Slacken the pivot screw.

Release the adjusting screws and move the 6 backplate until microswitch SW2 just activates then secure all screws.

Remove the spacers, then open and close the

oven door 5-10 times.

IMPORTANT: CHECK THE SWITCHES OPERATE IN THE FOLLOWING SEQUENCE AS MICROSWITCH SW3 MUST SWITCH THE LOAD CURRENT.

Closing the door:

Opening the door:

SW1 opens rst ● SW2 closes second ● SW3 closes third ●

SW3 opens rst ● SW2 opens second ● SW1 closes third ●

OVEN DOOR OPEN

OVEN DOOR CLOSED

SW3

SW2

SW1

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

TESTING

COMPONENTS

Convection Fan Motor & Controller17.2

Convection Fan Motor.17.2.1

The convection motor Is a 3-phase AC motor having a maximum speed of 7200 rpm controlled by a motor speed controller.

The windings are thermally protected and in the event of a thermal fault a trip inside the motor will operate and shut down the motor speed controller.

Motor Controller17.2.2

Provides a 3-phase AC switched mode drive to the convection motor and is controlled by a 0 - 10 Volt signal from the SRB. This allows the motor to be adjusted from approximately 1500 rpm to 7000 rpm in steps of 5%.

Door Open, 1500 RPM (20% @ 2V) ● Door Closed (not cooking), 3500 RPM (50% @ 5V) ● Door Closed (cooking), speed as specied by ●

program or setting up to a Maximum of 7000 RPM, 100% @ 10V)

LED Status display (A):17.2.3

Inverter O/No supply, LED OFF. ● Power On/Ready, LED ashes ON/OFF x1 per ●

second. Inverter Running, LED ON continuously. ● General Warning, LED ON/OFF x2 per second. ● Fault Condition, LED ON/OFF x10 per second. ●

Convection Fan Motor & Controller tests:

Disconnect and isolate the oven from the 17.2.4 electricity supply.

Allow the oven to cool down.17.2.5

Remove the oven casing.17.2.6

Ensure that the High Voltage Capacitor is 17.2.7 discharged before commencing work.

Check the following:17.2.8

Electrical supply into motor controller.

Three phase connections to motor.2 Speed Controller connections to SRB.3 Motor thermal cut-out (short circuit).4 Motor rotates freely/not seized.5 Motor winding resistances:6

Blue-Black 3 - 4 Ohms. ● Black-Brown 3 - 4 Ohms. ● Brown-Blue 3 - 4 Ohms. ● Black or Brown or Blue to Earth (Open circuit). ●

L2/N

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

SPARES &

REPLACEMENT

OVEN COMPONENTS18

DANGER:

BEFORE REMOVING THE OVEN CASING, ISOLATE THE OVEN FROM THE MAINS

ELECTRICITY POWER SUPPLY; SWITCH OFF, DISCONNECT OVEN PLUG FROM WALL SOCKET, TURN OFF ISOLATOR SWITCH TO DISCONNECT FIXED WIRED OVENS AND LOCKOFF.

WARNING:

ALLOW OVEN TO COOL AND

OBSERVE AND FOLLOW ALL SAFETY

PRECAUTIONS INCLUDING THOSE DESCRIBED UNDER THE SAFETY REGULATIONS SECTION OF THIS MANUAL BEFORE ATTEMPTING A SERVICE OR REPAIR.

CAUTION MICROWAVE

EMISSIONS:

DO NOT BECOME EXPOSED TO

EMISSIONS FROM THE MICROWAVE GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY.

63 80 69 77 41

63 Door oven

80 Microswitch SW1, SW2

69 Stirrer motor assembly RH

77 Wave guide RH

41 Overheat stat oven cavity

78 Air intake lter (front)

79 Hinge assembly door RH

16 SRB Smart Relay Board with in-built 1.25A fuse (Located in front of 24V transformer)

10 Filter 16A threaded

84 HV capacitor

77 Wave guide LH

57 Temperature sensor (Thermocouple) oven cavity

69 Stirrer motor assembly LH

82 Microswitch SW3

83 Controller convection fan motor

81 Hinge assembly door LH

78 79 16

10 89

77 57 69 82

84 10 83 81

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

SPARES &

REPLACEMENT

51 Magnetron cooling duct RH

11 Magnetron

33 Heater element x2 (connectors shown)

65 Motor assembly convection fan

24 Gland Power supply cable

52 Magnetron cooling duct LH

62 HT Diode assembly PCB

2 Fuse HT Transformer (10A)

85 Transformer

69 Cooling fan motor

9 Capacitor 2µF (Blue) motor start

13 Overheat stat Magnetron

17 BTS Touch Screen PCB

6 Switch oven ON/OFF (rear connection)

21 Connector Terminal block Mains power supply

40 Speaker unit

10 Filter 16A

5 Fuse Control circuit (7A)

27 Ethernet port

7 Fuse (20A)

51 11 33 65 11 24 52

62 2 85 64 9 85 2 62 13

17 6 21 40

10 5 27 7 7

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

SPARES &

REPLACEMENT

SRB & BTS Circuit Boards19

SRB replacement19.1

Disconnect and isolate the oven from the 19.1.1

electricity supply.

Allow the oven to cool down.19.1.2 Remove the oven casing.19.1.3 Ensure that the High Voltage Capacitor is 19.1.4

discharged before commencing work.

Taking anti-static precautions, disconnect all 19.1.5

connections on the SRB.

Remove the PM (Personality Module) from the 19.1.6

SRB and place safely aside.

Release retaining screws and remove the SRB.19.1.7 Replace SRB and secure retaining screws.19.1.8 Reconnect all connections to the SRB, for details 19.1.9

see ‘SRB Terminal Locations’ (Electrical Circuits section).

Ensure the thermocouple negative (-)

connection (white) and positive (+) connection (green) are tted the correct way round or the oven temperature readings will be wrong.

Ret the PM removed from the old SRB to the

new SRB. Refer to the following PM replacement if a new PM is tted.

electricity supply.

discharged before commencing work.

connections on the BTS.

the BTS and place safely aside.

BTS assembly (4).

new BTS. Refer to the following PM replacement if a new PM is tted.

retaining nuts.

details see ‘BTS Terminal Locations’ (Electrical Circuits section).

BTS replacement19.2

Disconnect and isolate the oven from the 19.2.1

Allow the oven to cool down.19.2.2 Remove the oven casing.19.2.3 Ensure that the High Voltage Capacitor is 19.2.4

Remove the top front panel.19.2.5 Taking anti-static precautions, disconnect all 19.2.6

Remove the PM (Personality Module) (3) from 19.2.7

Release the four retaining nuts and remove the 19.2.8

Ret the PM removed from the old BTS to the 19.2.9

Replace the BTS assembly and secure with the 19.2.10

Reconnect all connections to the BTS, for 19.2.11

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

SPARES &

REPLACEMENT

PM (Personality Module) 19.3

replacement

The PM on the SRB contains the Firmware. The PM on the BTS contains the Firmware, Oven Serial Number, Temperature Calibration, Cooking Programs, Application Icons and the Recipe Images.

With a new PM tted and casing retted, switch 19.3.1 on the oven and tap the screen to hold and check the BTS and SRB versions (1) are the latest release, if not, execute a Firmware update using the latest versions. For details see ‘Firmware Updates’ (Servicing section).

Tap the top right of the screen to bypass the 19.3.2 preheat stage (2).

Enter the service password and select OK to 19.3.3 display the Settings menu, see (3).

Select the USB symbol (4).19.3.4

Slide the Merrychef badge upwards and insert 19.3.5 the USB Memory Stick into the slot (5).

Once the USB has stopped ashing, select the 19.3.6 required USB recipe symbol (6).

Select the Application Icons le to download (7). 19.3.7 Note; a tinted band over a le name indicates the le is not valid for that oven.

Check the le information shown is correct 19.3.8 before selecting OK (8), if not, select ‘X’ and locate the correct le.

When completed, select recipes to load the 19.3.9 cooking programs (9). Once the programs are loaded the oven restarts.

Enter the Date & Time settings (10). For details 19.3.10 see under ‘Oven Control Settings’ (Product Information section).

Turn the oven switch OFF/ON.19.3.11

Remove the USB and keep in a safe place. 19.3.12 Reposition the USB cover.

6 7

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

2425

36 37

3839

58 59

5859

776970

SPARES &

REPLACEMENT

SPARE PARTS EXPLODED VIEW20

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

SPARES &

REPLACEMENT

SPARE PARTS21

Parts list & recommended minimum stock holding & Service Kits

Exploded

BOM No.

1 105005 M3 CAGE NUT 10 EA 10 30 60

4 30Z0240 MICROSWITCH 2 EA 2 6 12 2 4

6 30Z0503 SWITCH ON/OFF ROCKER DPST 1 EA 1 3 6 1 1

7 30Z1177 20 AMP LITTLEFUSE FLM020 2 EA 2 6 12 2 4

8 30Z1178 30A FUSE HOLDER 2 EA 1 3 6 1 2

10 30Z1340 FILTER 16A SCREW MOUNT 5 EA 2 6 12 1 4

11 30Z1415 MAGNETRON 2M303H 2 EA 1 3 6 1 2

12 30Z1425 LV TRANSFORMER 1 EA 1 3 6 1 2

13 30Z1427 MAGNETRON OVERHEAT STAT 2 EA 1 3 6 1 1

14 30Z1430 MICROSWITCH (LARGE) 1 EA 1 3 6 1 1

15 30Z1439 RELAY 12V OMRON 2 EA 1 3 6 1 2

16 30Z5000 SMART RELAY BOARD SRB 1 EA 1 3 6 1

17 30Z5002 TOUCH SCREEN & PCB 1 EA 1 3 6 1

18 31Z0115 INSULATOR PAD 2 EA 2 6 12

19 31Z0630 3 WAY CHOC BLOC 1 EA 2 6 12 1

20 31Z0186 SILASTIC BLACK (DOOR SEAL) TUBE 1 3 6 1 1

21 31Z0477 4 WAY MAINS TERMINAL BLOCK 1 EA 1 3 6 1

22 31Z0600 USB ADAPTOR MODULE 1 EA 1 3 6 1

23 31Z0620 BTS UI SRB CABLE (WHITE) 1 EA 1 3 6 1 1

24 31Z1255 PG21 CABLE GLAND BLACK 1 EA 1 3 6

25 31Z1256 PG21 CABLE GLAND NUT 1 EA 1 3 6

26 31Z1259 SHEET COVER CAP 12MM DIA 4 EA 4 12 24

27 31Z1307 ETHERNET HOLE PLUG 1 EA 1 3 6

28 31Z3154 M4x6 SET SCREW S/S A2 (IMPINGER) 2 EA 1 3 6 1

29 32Z1066 DOOR HANDLE 1 EA 1 3 6

30 32Z4028 HALF SIZE GASTRONOM DISH 1 EA 1 3 6

31 32Z7062 PERSONALITY MODULE SRB e4 1 EA 1 3 6 1

32 32Z7065 PERSONALITY MODULE BTS e4 1 EA 1 3 6 1

33 DR0005 4 COIL DUAL HEAT ELEMENT 3.2kW 1 EA 1 3 6 1

34 DR0006 REED SWITCH 1 EA 1 3 6 1 1

35 DR0007 MERRYCHEF BADGE 1 EA 1 3 6

36 DR0008 MERRYCHEF BADGE SLIDER 1 EA 1 3 6

37 DR0009 MERRYCHEF BADGE GUIDE 1 EA 1 3 6

38 DR0010 MERRYCHEF BADGE SEAL 1 EA 1 3 6

39 DR0011 TOUCHSCREEN OVERLAY 1 EA 2 6 12 1

40 DR0021 HARMONISED SPEAKER 1 EA 1 3 6 1

41 DR0043 OVERHEAT STAT LARGE 1 EA 1 3 6 1 1

42 DV0061 IMPINGER THUMB NUT 2 EA 2 6 12

43 DV0168VIT DOOR CHOKE PRESSED (VITREOUS) 1 EA 0 1 2

44 DV0187 TOP PANEL (PRESSED) 1 EA 0 1 2

45 DV0202 CERAMIC PLATE RETAINER 4 EA 4 12 24 4

46 DV0239 IMPINGER FIXING - FAST THREAD 2 EA 1 3 6 1

47 DV0275 RACK V3 1 EA 1 3 6

48 SA3113 DOOR SEAL HT 1 EA 1 3 6 1 1

49 DV0366 GREASE FILTER HOUSING (EASY OUT) 1 EA 1 3 6

50 DV0370 LOWER IMPINGER HANDLE 1 EA 1 3 6 1

51 DV0397 CAST REAR DUCTING RH 1 EA 0 1 2

52 DV0403 CAST REAR DUCTING LH 1 EA 0 1 2

53 DV0437 LOWER FASCIA FINISHED 1 EA 0 1 2

54 DV0452 CAPACITOR CLIP 2 EA 2 6 12

Part Number

Description

Qty

Per

Oven

Unit

1-10

Ovens

11-50

Ovens

51-100

Ovens

1st Aid/

To Go

Box

Service

Centre

Kit

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

REPLACEMENT

SPARES &

Exploded

BOM No.

55 DV0467 SIDE PANEL RH 1 EA 0 1 2

56 DV0468 SIDE PANEL LH 1 EA 0 1 2

57 DV0661 THERMOCOUPLE (OVEN) 1 EA 1 3 6 1 1

58 DV0666 STIRRER COVER - CERAMIC 2 EA 2 6 12 2 2

59 DV0692 SEAL - CERAMIC COVER 2 EA 2 6 12 2 2

60 DV0700 DOOR SKIN 1 EA 0 1 2

61 MC3175 OVEN TRAY - SQUARE 1 EA 1 3 6

62 30Z5008 DIODE PCB ASSY 2 EA 2 6 12 2 2

63 PSA111 DOOR ASSY (PRESSED) 1 EA 0 1 2

64 PSA1122 COOLING FAN SUB-ASSEMBLY 1 EA 1 3 6 1

65 PSA1180 HOT AIR MOTOR ASSY 1 EA 1 3 6 1

66 PSA2101 TOP IMPINGER PLATE SS 1 EA 0 1 2

67 PSA246 DOOR + CHOKE ASSY (PRESSED) 1 EA 0 1 2

68 PSA266 IMPINGER PLATE LOWER 1 EA 0 1 2

69 PSA288 STIRRER MOTOR ASSY (PINNED) 2 EA 2 6 12 2

70 PSA291 STIRRER ASSY (PINNED) 2 EA 2 6 12 2

71 RMC6104 LEG 1 EA 0 1 2

72 SA3105 GASKET KIT 1 EA 1 3 6 1

73 SA329 REAR PANEL ASSY 1 EA 0 1 2

74 SA340 GREASE FILTER CARTRIDGE 1 EA 1 3 6

75 SA351 UPPER CAT ASSY 1 EA 0 1 2

76 SA353 LOWER CAT ASSY 1 EA 0 1 2

77 SA374 CAST WAVEGUIDE ASSY 2 EA 0 1 2

78 SA390 AIR FILTER ASSY 1 EA 1 3 6 1 1

79 / 81 PSR101 EIKON DOOR HINGE KIT 1 EA 1 3 6 1

80 / 82 PSR102 EIKON M/SWITCH BRACKET KIT 1 EA 1 3 6 1

Part Number

Description

Qty

Per

Oven

Unit

1-10

Ovens

11-50

Ovens

51-100

Ovens

1st Aid/

To Go

Box

Service

Centre

Kit

eikon e4 208V & 240V 60Hz - USA - Unique Parts

85 30Z1230 60HZ TRANS MULTI TAP 2 EA 2 6 12 2

83 30Z1293 MOTOR SPEED CONTROLLER (USA) 1 EA 0 1 2 1

84 30Z1330 0.88uF 2500V CAPACITOR 2 EA 2 6 12 2 2

15 30Z1439 OMRON RELAY 12V 1 EA 1 3 6

86 31Z1266 PLUG & LEAD ASSY (SUBWAY) 1 EA 1 3 6

2 30Z1445 10A UL Fuse 2 EA 2 6 12 2 4

3 30Z0285 Fuseholder 1 1/4in 3 EA 1 2 4 1 2

5 30Z1444 7A UL Fuse 1 EA 2 6 12 2 4

9 30Z1446 2uf UL Starter cap 1 EA 2 6 12 1 2

eikon e4 220Volts 60Hz - South America - Unique Parts

85 30Z1230 60HZ TRANS MULTI TAP 2 EA 2 6 12 2

83 30Z1293 MOTOR SPEED CONTROLLER (USA) 1 EA 0 1 2 1

84 30Z1330 0.88uF 2500V CAPACITOR 2 EA 2 6

86 31Z1266 PLUG & LEAD ASSY (SUBWAY) 1 EA 1 3 6

2 30Z0217 FUSE 1in 10A HRC 2 EA 2 6 12 2 4

3 30Z0231 FUSEHOLDER 1in (13A) 3 EA 1 2 4 1 2

5 30Z0394 FUSE 1in 7A HRC 1 EA 2 6 12 2 4

9 30Z1298 CAPACITOR - MOTOR START (COOLING) 1 EA 2 6 12 1 2

12 2 2

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

ERROR CODES DISPLAYED22

Error Code

E 101

E 102

E 103

Error Condition Description Trigger Possible Causes

The current

Magnetron failed to energise

Detects a magnetron is not working correctly

measured by the current sensing transformer was outside of

Failure of component/s in the microwave circuit

tolerance.

If some current >1A, one or more heater elements could have failed. If current measured <1A possible wiring fault stopping power reaching element.

Cooling fan failed. Cooling fan wired incorrectly. Inlet air too hot. Blocked inlet lter.

Heater incorrect current

Ambient overheat >70°C

Detects a heating element is not working correctly

Detects if the controls area is operating above temperature

The current measured by the sensing transformer on the SRB was <1A when heating cycled on or >1A when heating cycled o.

The ambient temperature measured on the BTS and SRB was >70°C

Error Level

Critical

System Response

Display error message until system is power cycled.

Display error message until ambient controls area temperature is below 60°C

E 104

E 105

E 106

E 107

Magnetron / Cavity Overheat

Supply voltage high / low

Cavity reaches 25°C above setpoint once it has been controlling at setpoint

Communication error

Detects if the cavity and magnetrons are above temperature

Detects if the power supply voltage is outside specication

Detects if the cavity temperature has risen above limits

No communication can be made between the BTS and SRB

Cavity and magnetron overheat thermostats

The power supply to the oven voltage sensor on the SRB measures too high / low

The setpoint of the oven was exceeded

Loss of communication between the SBR and BTS

Cooling fan failed.

E103 / E106 not triggering. Failed SRB. Magnetron failure. Wiring / connection fault.

Blocked Inlet lter.

Incorrect mains voltage. Poor internal / external wiring connections. Faulty SRB.

Cavity re. Failed convection fan. No impeller or loose impeller on convection fan.

SRB / BTS connection cable unplugged or damaged. Faulty BTS or SRB.

Critical

Display error message until service call and the magnetron cools down or the cavity stat is reset.

Display error message until system power cycled.

Display error message until system is power cycled.

FAULT FINDING

E 108 BTS PM error

Wrong PM found / no PM found

The BTS or SRB either has an incorrect PM (Personality Module) tted or no PM is tted

The PM has been changed and is incorrect. The PM has been removed.

Critical

Display error message until system is power cycled.

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

Error Code

Error Condition Description Trigger Possible Causes

Error Level

System Response

E 110

E 111

N/A

SRB version conict

Cavity sensor error

Oven door open longer than 1 min.

N/A Air Filter removed

SRB rmware version incompatible with BTS version

Cavity sensor broken / unplugged

Oven door open. Oven inoperable.

Air lter not tted. Oven inoperable.

The BTS has found that the rmware running the SRB is not supported.

The controller is reading an open circuit across the thermocouple input

Break in switched feed on SRB

Filter not tted.

Firmware update has been carried out to the BTS and the SRB has not been updated to match.

The thermocouple is not connected. The thermocouple is broken open circuit. Failed SRB.

Door left open. Failed door switch/s or SRB. Faulty wiring or connection.

Failed reed switch/s or SRB. Faulty wiring or connection.

Critical

Warning

Display error message until system is power cycled.

Display warning message until door is closed.

Display error message until lter replaced.

FAULT FINDING

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

SRB & BTS Circuit Boards23

BTS LEDs23.1

Run - Pulsing 1 second ash, indicating that the ● board has booted up.

Power - Lit to show that there is a power supply ● from the SRB.

P-Bus - Irregular ashing, indicating data ● communication with SRB.

C-Bus - Lit to show data being loaded from the ● PM onto the BTS.

LD5 - Lit to show. ●

LD5

Power, Run, P-Bus, C-Bus.2

4 5 6

BTS Terminal Locations23.2

X6 - Speaker3 X5 - USB socket4 X4 - Communications to SRB5

X11 - Screen backlight6 X13 - Touch pad7 X9 - Display Screen PCB8

ELECTRICAL

CIRCUITS

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

ELECTRICAL

CIRCUITS

SRB LED’s23.3

P-Bus - Irregular ashing, indicating data ●

communication with BTS.

Run - Pulsing 1 second ash, indicating that the ●

board has booted up.

12v & 5v - Lit to show voltage outputs from ●

inboard transformer.

Relay & Triac - Lit to show that a signal has been ●

sent to energise that component.

Cooling fan.

Convection fan.2 Stirrer.3 5v supply.4 12v supply.5 Heater safety.6 Heater drive.7 P-BUS: ashes when data is being sent / 8

received. RUN: 1 second ash.

Oven Door.

Microwave safety relay.10 Microwave 2 drive.11 Microwave 1 drive.12

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

ELECTRICAL

CIRCUITS

SRB Terminal Locations:23.4

X3 - Output for e4 Convection Fan Controller.1 X101 - Voltage Selection Relay coil feeds.2 X18b - Air intake Filter Reed Switch.3 X18e - Right Magnetron Thermostat.4 X18d - Left Magnetron Thermostat.5 X18c - Cavity Overheat Thermostat.6 X18a - On/O Switch.7 X14 - Cavity Temperature Thermocouple.8 X5 - Fan RPM Input.9 X13 - P Bus, Ethernet Port.10 X12 - C Bus, Development PC Port.11 X11 - P/C Bus, BTS Cable.12 X1 - 24V supply from Low Voltage Transformer.13 X8 - Cooling Fan.14 X17 - Not used.15 X20 - Microwave Stirrers.16 X9 - Mains Output, Convection Fan Controller.17 X103.1 - Mains Output to Low Voltage 18

Transformer.

X103 - Mains Input, Live & Neutral.

X2.1 - Mains Input, Live for Heaters.20 X2.2 - Mains Output, Live to Heaters.21 X102a - Mains Input, Neutral for Magnetron 22

Transformers & Monitor Door Switch.

X102b - Mains Output, Neutral to Magnetron

Transformers & Monitor Door Switch.

X4a - Door Switch signal from Secondary Door

Switch (Live for Magnetron Transformers).

X10 - Connector Block for door switches.

X4b - Live for Magnetron Transformers.26

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

Aux

Power

RED( 0-10V ) GREEN( 10V ) BLUE( GND )

Convection FAN

Heater Supply

M.W. Supply

Neutral In

Interblock Switch Connector

24VAC Supply

On/Off

Air filter

Overheat Cavity

Cooling Fan

Magnetron stirrer motor 1

Magnetron stirrer motor 2

Heater Supply out

MW1

MW2

Neutral MW1 Interlock Switches

Temperature Input

P/C - Bus

C - Bus

P - Bus

RJ-45

RJ-12

RJ-11

17 16

18 19

20 22 23

31 45

Neutral MW2

25 26

10 29

30 44

58 59

60 61 62 63

64 65

66 67 68

69 70

71 72

73 74

Overheat MW1

Overheat MW2

SRB Transformer

Delta

Star

3 15

PRI

TR3

Heater

Microwave

Control

For Dual phase or 3 phase Delta ovens

Wire No's 4 & 6

connect to L1/L2

Wire No 5

For single phase ovens

Wire No's 4,5 & 6

connect to L1/L2

MW1

51 52

Voltage selection relay

37 38

MW2

Right Hand Side Switch assly

SW2 Secondary

SW1 Monitor

BTS

Coms modules

60Hz: Jumper on X5.1-X5.2

X2.1

X2.2

X4a

1 2

X4b

X4a

X2.1

Voltage selection

Voltage-selection-Relay-driver.Sch

Relays driver

1 2 3 4

X101

1 2 3

X102bX102a

X102(N)

Common Connector block

interlock switches

1 2 3

X10

Power supply

Power-supply.Sch

1 2

12V;5V;3.3V

12V 5V

Thermocoupler input

Thermocoupler-input.Sch

1 2

X14

X2.2

C/B Bus

C-P-Bus.Sch

C-Bus

C-P-Bus.Sch

P-Bus

C-P-Bus.Sch

Safety relay Supply

Safety-relay.Sch

Air filter feedback

feedback.Sch

+12V

X18e.2

X18a.2

X18b.2

X1.1 X1.2

MCU

MCU.Sch

X11

X12

X13

Power switch feedback

( Heater & M.W. only)

Motor feedback

feedback.Sch

1 2 3

1 2

X18b

1 2

X18c

1 2

X18d

1 2

X18e

1 2 3

X18a

Safety Relay Heater

Safety-relay.Sch

Triac 16A output

Triac-output.Sch

Safety Relay M.W.

Safety-relay.Sch

Current Sense

Current-Sense.Sch

Hybrid Relay 1

Hybrid-Relay.Sch

Door switch

door-switch-detection.Sch

Lcs_Heater

Lcs_MW L'cs_MW

Safety Relay Aux

Safety-relay.Sch

Line voltage monitoring

Line-voltage-monitoring.Sch

X103

Triac 1A output

Triac-output.Sch

Triac 2A output

Triac-output.Sch

Triac 1A output

Triac-output.Sch

Convection Fan

0-10V-out.Sch

0...10V passiv isolated output

1 2 3

X17

1 2 3 4

X20

X8.1

X17.1

X20.1

X103.1

Hybrid Relay 2

Hybrid-Relay.Sch

ELECTRICAL

CIRCUITS

CIRCUIT DIAGRAMS24

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

87654321

Cooling Fan

Magnetron stirrer motor 1

Magnetron stirrer motor 2

Heater Supply out

MW1

MW2

Neutral MW1 Interlock Switches

Temperature Input

P/C - Bus

C - Bus

P - Bus

RJ-45

RJ-12

RJ-11

31 45

Neutral MW2

MW2

Diodboard

MW1

Diodboard

30 44

58 59

60 61 62 63

MW1 left hand side (From the front)

MW2 right hand side (From the front)

230

64 65

67 66 68

Convection fan

8 9 10

L N

Stirrer motor

BLUE( GND )

RED ( 0-10V )

GREEN( 10V )

29 11

Heater 1.6kW

78 77

Heater 1.6kW

COOLING FAN

blue

black

brown

blue

brown

MW2

Diodboard

MW1

Diodboard

56MW1 left hand side (From the front)

MW2 right hand side (From the front)

208

240

208

60Hz

50Hz

25 26

On/Off

Air filter

Cavity

69 70

Cavity

71 72

MW1

+ -

MW1

51 52

Voltage selection relay

37 38

MW2

Right Hand Side Switch assly

Left Hand Side Switch assly

SW2 Secondary

SW1 Monitor

SW3 Primary

Note

Switches Shown in

Door Closed position!

BTS

Coms modules

73 74

MW2

60Hz: Jumper on X5.1-X5.2

ELECTRICAL

CIRCUITS

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

ELECTRICAL

CIRCUITS

POWER CONNECTIONS e424.1

Product e4

Single Phase & Neutral Model

Microwave 1500W

Convection heater 3.2kW

Neutral

Live

Heater circuit

Microwave circuit

Control circuit

Heater circuit

Microwave circuit

Control circuit

Product e4

Neutral

Twin Phase & Neutral Model

Microwave 1500W

Heater circuit

Convection heater 3.2kW

Microwave circuit

Control circuit

L1 (Phase 1)

Heater circuit

Control circuit

L2 (Phase 2)

Microwave circuit

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

ELECTRICAL

CIRCUITS

CONTROL CIRCUIT e424.2

Fuse 3

7 Amp

Filter 1

Safety Aux.

6062 58

Stirrer

Cooling fan

6163 59 65 17 19

64 64 64 64 16

10V IN

0-10V OUT

Convection fan controller

0V OUT

TR3

1.25A

18 69

24V

out

12V

72 73 2725

CAV O/H

70 71 74 2826

MW1 O/H

MW2 O/H

12V

ON/OFF switch

Air lter Reed Cont.

Filter 1

Filter 1. Connector view

N L

Input detection for

Safety Relay

supply

control

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

ELECTRICAL

CIRCUITS

HEATER CIRCUIT e424.3

Fuse 1

20 Amp

Filter 3

Safety Heater Relay.

relay

x2.1

Processor controlled

x2.2

29 78 78

input for

x14.1

Temperature

thermocouple

x14.2

Heater Element

Filter 3

Filter 3. Connector view

N L

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

ELECTRICAL

CIRCUITS

MICROWAVE CIRCUIT e424.4

RHS SW1 normally

closed

L SINGLE PHASE MODEL

L2 TWIN PHASE MODEL

Fuse 2

20 Amp

Filter 2

2221

X.10

LHS SW3 normally

x4a

RHS SW2 normally

open

Door Switches shown in

door open position

Filter 2. Connector view

N L

Filter 4. Connector view

N L

Filter 5. Connector view

N L

x102b

Safety Relay

Microwave. Powered

by Safety Supply relay

x102a

Filter 2

Current Sense

Hybrid

Relay

x4b2 x4b1

30 44

Fuse 5

10 Amp

32 46

Filter 4

33 48

34 47

Filter 5

To SRB E101 Sense

Fuse 4

10 Amp

5541

5642

5743

FAFA FF

MWMW

Diode BoardDiode Board

Filter 5

31 45

Filter 4

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

Commissioning the oven25

Initial installation25.1

Unpack the Oven and check for damage.1 Check Oven Accessories.2 Check location will provide adequate Ventilation.3 Locate Oven onto a strong, level, non-ammable 4

Surface.

Remove panels & check all wiring and components for

security.

Ret panels.

Position the Oven with a minimum air gap of 50mm, 7 sides & rear.

Check Electrical supply and connect.

Place a container of water within the oven and switch 9 it on.

Record Model version & check against serial plate.

Record BTS (UI) version.11 Record SRB version.12 Record Serial Number & check against serial plate.13 Enter Service Mode.14 Record Voltage & Frequency.15 Record Magnetron Current Draw.16 Check for Microwave leakage.17 Record Heater current.18 Check door opening on display.19 Check lter removal on display.20 Check fan speed.21 Turn o the oven and remove the water.22 Switch on oven and run up to temperature.23 Operate Oven, Cooking a Standard Batch.24 Supply User information & contact details to Customer.25 Instruct Users with an Overview of the equipment, 26

Operation & Safety (Hazards).

Complete Service Report.

After Service25.2

Complete the following checks after the Oven has been Serviced/Repaired/Tested before connecting to the mains electricity power supply:

All internal electrical connections are correct (see 25.2.1

wiring diagrams).

All wiring insulation is correct and is not touching any 25.2.2

sharp edges.

All grounding connections are electrically and 25.2.3

mechanically secure.

All door safety interlocks are secure and mechanically 25.2.4

sound.

The door activates all of the door interlock switches 25.2.5

and in the correct order.

The door operation is smooth, and the arms run freely 25.2.6

in the slots.

The temperature sensor is correctly connected to the 25.2.7

SRB.

The casing is securely retted with no trapped wires.25.2.8

Before nishing a service call, recheck the following points:

Run the Recommission tests to ensure the oven is 25.2.9

functioning correctly and the touch screen is working.

Microwave emissions are below permissible limit of 25.2.10

5mW/cm².

The power output of the oven is checked in 25.2.11

accordance with the procedure.

The oven has correct 50mm (2 inches) air gap all 25.2.12 round and 50mm (2 inches) above. Air ow should not be restricted.

Complete the Service Report.25.2.13

COMMISSIONING

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

Service & Parts Manual original Instructions

Part Number 32Z3813 US

Issue 1

Correct disposal of this product (Waste Electrical & Electronic Equipment)

To prevent possible harm to the environment or human health from uncontrolled waste disposal, please separate this from other types of wastes and recycle it responsibly to promote the sustainable reuse of material resources.

Household users should contact either the retailer where they purchased this product, or their local government oce for details of where and how they can take this item for environmentally safe recycling.

Business users should contact their supplier and check the terms and conditions of the purchase contract. This product should not be mixed with other commercial wastes for disposal.

Merrychef reserves the right to change product specications without notice and accepts no liability for any inaccuracies, errors or ommissions contained herein.

Merrychef USA

1111 North Hadley RD

Fort Wayne

IN 46804 USA

Phone: 877/404 - 6872

Fax: 800/285 - 9511

e-mail: info@merrychefusa.com

www.merrychefusa.com

Merrychef e4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual