Mealstream
SERVICE MANUAL
MODELS Mealstream 501,502 & 503
MANUFACTURED FROM OCTOBER 2004
CAUTION MICROWAVE EMISSIONS
DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE GENER ATOR
OR PARTS CONDUCTING MICROWAVE ENERGY
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 1
SERVICE MANUAL
TABLE OF CONTENTS
Microwave safety precautions ................................................. 3
Safety code ............................................................................. 4
Product specifications ............................................................. 5
Installation instructions............................................................ 6
Main features ....................................................................... 7-8
Principal components: LHS..................................................... 9
Principal components: RHS .................................................. 10
Principal components: Top.................................................... 11
Principal components: Back view.......................................... 12
Principal components: door, roof and heater element .......... 13
Principal components: Cavity Parts & External Panels......... 14
Principal components: Electronic control panel assembly .... 15
Principal components: Tim Hortons Control panels .............. 16
Principal components: ( not shown in main views ) ............. 17
Principal components: Input wiring details ............................ 18
Principal components: Part no. identification charts ........19-21
Procedure for Microwave leakage test ............................. 22-23
Procedure for Power output measurement ........................... 24
Procedures for Principal Component tests ......................25-26
Procedure for Door interlock adjustment and test .......... 27-29
Procedure for building and fitting the door .......................30-34
Procedure for replacing door seal assembly.................... 35-36
Procedure for removing shelf runners & element cover ........ 37
Procedure for replacing Heater Element ............................... 38
Procedure for replacing Hot air Motor assembly ................... 39
Procedure for replacing Magnetron assembly ................. 40-41
Procedure for Testing Membrane panel circuit ..................... 42
Circuit diagrams ................................................................... 43
Error codes and diagnostics.................................................. 44
Appendix 1: Cleaning procedure...................................... 45-46
Appendix 2: MenuKey Download procedure......................... 47
Appendix 3: Temperature Sensor resistance data................ 48
Appendix 4: Recommended spares list................................. 49
Manual corrections and modifications ................................... 50
Merrychef, Mealstream and MenuKey are registered trademarks of Merrychef Ltd
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 2
MICROWAVE SAFETY PRECAUTIONS
CAUTION
WARNING TO SERVICE TECHNICIANS
PRECAUTIONS TO BE OBSERVED BEFORE AND DURING
SERVICING TO AVOID POSSIBLE EXPOSURE TO
EXCESSIVE MICROWAVE ENERGY
(a) Do not operate or allow the oven to be operated with the door open.
(b) Make the following safety checks on all ovens to be serviced before
activating the magnetron or other microwave source , and make repairs
as necessary:
1) interlock operation.
2) proper door closing.
3) seal and sealing surfaces (arcing, wear, and other damage).
4) damage to or loosening of hinges and latches.
5) evidence of dropping or abuse.
(c) Before turning on microwave power for any service test or inspection
within the microwave generating compartments, check the magnetron,
wave guide or transmission line, and cavity for proper alignment,
integrity and connections.
(d) Any defective or misadjusted components in the interlock, monitor, door
seal, and microwave generation and transmission systems shall be
repaired, replaced, or adjusted by procedures described in this manual
before the oven is released to the owner.
(e)(i) A microwave leakage check to verify compliance with the Federal
Performance Standard should be performed on each oven prior to
release to the owner. For U.S.A.
(e)(ii) A microwave leakage check to verify compliance with the Canadian
Regulation, HEALTH AND WELFARE, SOR/79 920 should be
performed on each oven prior to release to the owner. For CANADA.
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 3
SAFETY CODE
This manual is designed to assist engineers who have been on a recognised product
familiarisation and training course run by Merrychef. It has been prepared to offer technical
guidance for the Mealstream range of Combination Microwave Ovens.
Please remember that it is wiser not to attempt a service task if you are unsure of being able to
complete it competently, quickly, and above all safely.
To avoid injury to yourself, and to protect the appliance from possible damage, please follow this
Safety Code when servicing these ovens.
Before attempting to repair the oven, check it for microwave leakage.
Check that the oven is not emitting microwaves, even when supposedly not in
operation.
Check that the oven is not operating continuously, whether the display indicates
cooking or not.
Always discharge the HT capacitors before working on the oven using a suitably
insulated 10 MΩ Resistor.
Before removing any covers from the oven, do all of the following.
• Switch off the mains supply and remove the plug from the wall socket.
or
• If the oven is hard wired, ensure that the power is turned off at the isolator switch.
Note:
The On/Off switch on the oven is not adequate protection against electric
shock, as it does not isolate all of the internal wiring from the mains.
Upon completion of a service on a Mealstream oven, or before reconnecting the appliance to the
electrical supply for testing, check all of the following points:
• All internal electrical connections are correct (see wiring diagram Page 44-47).
• All wiring insulation is correct and is not touching a sharp edge.
• All grounding connections are electrically and mechanically secure.
• All door safety interlocks are secure and mechanically sound.
• The door operation is smooth, and the arms run freely in the slots.
• The door activates all three of the door interlock switches in the correct order
(see pages 27-29).
• The temperature sensor is correctly connected to the Power PCB.
Before finishing a service call, recheck the following points:
• All of the electronics are functioning correctly, and all of the touch pads are working.
• Microwave emissions are below permissible limit - 4 mW/cm².
• The power output of the oven is checked in accordance with page 24.
• Oven has correct 2 inch ( 50mm ) air gap all round and 2 inch ( 50mm ) above.
Air flow should not be restricted. (see page 6).
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 4
PRODUCT SPECIFICATIONS
Model Number: CTM3 v f p c A MK B C US
Example: CTM3246015AMKCUS
CTM3
Merrychef USA, Mealstream 503 model, combination microwave oven
240V, 60Hz, single phase supply, Series 5 electronic controls,
American power supply lead, MenuKey fitted, small Cavity filter, ( USA model )
v
Voltage f Freq.
p
Phase
c
Controls
A
Power
Supply
Lead
20 = 208V
24 = 240V
50 = 50 Hz
60 = 60 Hz
2 = 2 phase
1 = 1 phase
5 = Electronic
A=
American
* MK, B & C only on models fitted with MenuKey and/or Filters
Power
Requirements
208Volts
240Volts
Power Output Microwave 100%
Convection
Combination
External
Dimensions
Height
Width
Depth
208V ac 60Hz 30Amp 2P & G
240V ac 60Hz 40Amp 2P & G
1425W
3000W
1425W + 3000W
30 inches ( 765mm )
29.5 inches ( 770mm )
25 inches ( 635 mm)
MK*
MenuKey
MK =
MenuKey
Fitted
B,C*
Cavity
Filter
Type
BC= 502
Full filter
C = 503
Small filter
US
Merrychef
USA
model
Manufacturers
recommended
clearances
Height
Width
Depth
Internal
Dimensions
Height
Width
Depth
Capacity
Weight Nett
Gross packed
Construction Cavity
Casework
Settings Microwave
Temperature
Timer
Programs
Mealstream Ovens Pt. No. 32Z3486 Issue 1
32 inches ( 815 mm )
31.5 inches ( 795 mm )
27 inches ( 685 mm)
10.2 inches ( 260mm )
19.3 inches ( 490mm )
14.2 inches ( 360mm )
1.62 ft³ ( 45.86 litres )
198 lb.s ( 90 kg )
227 lbs ( 103 kg )
304 Stainless Steel
100%,75%,50%,25%, Convection only
Off, 300°F, 350°F, 400°F, 440°F, 480°F
Up to 30 minutes per stage
Cook Programs can have 3 cooking stages of up to 30
minutes for each stage
Page 5
INSTALLATION INSTRUCTIONS
Installation Instructions for Mealstream Combination Ovens
Power Supply Requirements
The Mealstream Series should be connected to a suitable electricity supply, which can cope
with the switching-on surge that occurs with certain types of catering equipment, including
microwaves. Because of this requirement, we strongly recommend that a separate, suitably
rated supply is installed for the oven.
The supply for the oven should be fitted with a Type "C" or Time Delay circuit breaker,
rated at:
50 Amp for 208V electrical supply ( 2PH + GND )
50 Amp for 240V electrical supply ( 2PH + GND )
30 Amp for 208V electrical supply ( 2PH + GND )
30 Amp for 240V electrical supply ( 2PH + GND )
If the oven is hard-wired to the supply, a double-pole isolator switch with a contact gap of at
least 1/8 inch ( 3 mm ) should be fitted.
Grounding requirement
This appliance must be connected to a grounded, metallic, permanent wiring system, or an
equipment grounding conductor should be run with the circuit conductors and connected to the
equipment grounding terminal or lead on the appliance.
Canada models
US models
Positioning the Oven
In order to maintain adequate ventilation for air intake
and exhaust, and to allow access for cleaning filters,
you must allow a minimum of 2 inches ( 50 mm )
clearance at the sides and rear of the oven,
and at least 2 inches ( 50 mm ) above.
Air intake temperature should not exceed 110°F/45°C
excessive temperature will lead to reduced operating
duty cycle, or premature ageing of internal components.
Failure to comply with these conditions will invalidate
the warranty.
NEVER Install an oven above fryers,
grills, griddles or any other
major heat source.
NEVER Stack machines on top of
each other. Always use a
double stand or a separate
shelf.
ALWAYS Place containers in the cavity
carefully - impact damage
may chip the vitreous enamel
coating on the runners and
baffle plate.
Note:
The minimum recommended
clearance required for air flow
31.5ins
27ins
32ins
16ins
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 6
MAIN FEATURES
a
b
c
d
e
k
On/Off SWITCH
a
This is used to turn the oven On or Off.
IT DOES NOT ISOLATE INTERNAL
WIRING FROM THE MAINS SUPPLY.
EXHAUST VENTS
b
Allows exhausted air from the magnetron
cooling system to escape.
HOT AIR FAN
f
Situated behind the baffle plate, and
circulates the hot air through the baffle
plate, over the heating element, and around
the edge of the baffle plate back into the
cavity.
RATING PLATE
g
b
f
g
j
i
h
OVEN CAVITY
c
The oven cavity is mainly constructed
from stainless steel panels. It must be
kept clean.
BAFFLE PLATE
d
Forms the inside rear of the oven and
covers the hot air circulation fan. This
must be cleaned on a regular basis, and
kept free of debris. See page 16 for more
details.
RUNNERS
e
These are mounted on each side of the
oven cavity to support the rectangular
racks or oven trays.
Mealstream Ovens Pt. No. 32Z3486 Issue 1
The rating plate is situated on the rear of
the oven, and states the Model, Serial
Number, Electrical Ratings and
Manufacturers telephone number.
DOOR
h
The door consists of a thermally insulated
inner section, and an additional air gap
provided by a twin skinned door front to
lower the surface temperature.
DOOR SEAL
i
ELECTRICAL SUPPLY CORD
j
Electrical supply cord is situated on the rear
of the oven,
AIR FILTER
k
Main intake for cooling air for internal
components. Must be clear of obstructions.
Page 7
MAIN FEATURES
Electronic control panel
a
j
i
h e
Stage LED's
a
Program & Time Display
b
Convection Pad
e
Power Pads
f
Time / Preset Pads
g
Temperature Set Pads
h
Cancel / Callback Pad
i
b
f g
n
Program Pad
j
MenuKey™
n
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 8
PRINCIPAL COMPONENTS
Left side
1
1A
2
2A
3A
3
4
4A
14
5
5A
6
7
8
9
No Description 208V 240V
1 Fuse holder 30Z0231 30Z0231
1A Fuse 10 amp 30Z0217 30Z0217
2 Fuse holder 30Z0231 30Z0231
2A Fuse 10 amp 30Z0217 30Z0217
3 Fuse holder 30Z0285 30Z0285
3A Fuse 1 amp 30Z0957 30Z0957
4 Fuse holder 30Z1178 30Z1178
4A Fuse 20 amp 30Z1177 30Z1177
5 Fuse holder 30Z1178 30Z1178
5A Fuse 20 amp 30Z1177 30Z1177
6 Electrical supply terminal block 31Z0149 31Z0149
7 Filter ( Heater circuit ) 30Z0997 30Z0997
8 Filter ( Microwave circuit ) 30Z0997 30Z0997
9 Door spring 40C1141 40C1141
10 Door arm stop assembly 11C0279 11C0279
11 Microswitch ( Primary ) 30Z0240 30Z0240
12 Door hinge assembly ( LH )B 11C0167 11C0167
13 Door arm assembly 11C0300 11C0300
14 Microswitch ( Monitor ) 30Z0240 30Z0240
13
12
11
10
Note B
See page 17
for parts
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 9
PRINCIPAL COMPONENTS
Right side
95
22
59
15
16
17
19 18
No Description 208V 240V
9 Door spring 40C1141 40C1141
15 Door arm assembly 11C0300 11C0300
16 Door hinge assembly ( RH )
B
11C0166 11C0166
17 Micro-switch ( Secondary ) 30Z0240 30Z0240
21
20
90
Note B
See page 17
for parts
18 Door arm stop assembly 11C0279 11C0279
20 Steam pipe 40C1023 40C1023
21 Steam vent guard 790061 790061
22 Temperature sensor 50E123 50E123
59 Rubber stop 31Z1150 31Z1150
90 Cavity Vent Pipe 40C1013 40C1013
95 Diode Board Assy. with leads 11M0325 11M0325
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 10
PRINCIPAL COMPONENTS
Top view
87
23
24
63
26
27
60
61
87
23
24
63
26
27
28
No Description 208V 240V
23 Magnetron (Panasonic) 30Z1171 30Z1171
24 Resistor 470 R 30Z0283 30Z0283
26 Capacitor 0.88µf (2500V) 30Z0861 ——-
27 Transformer ( Multi) 30Z1230 30Z1230
28 Twin blower motor 30Z1145
60 25mm OD Flexible conduit 314402
61 20mm OD Flexible conduit 314401
62 Capacitor clip (99mm) 31Z0176
63 Filter 30Z0997
87 Magnetron Thermal Trip 2571016
62
30Z1145
314402
314401
31Z0176
N/A
2571016
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 11
PRINCIPAL COMPONENTS
Back view
104
88
64
65
94
No Description 208V 240V
64 Hot air motor Service Kit 10C0192
65 Capacitor (motor start ) 6µF 30Z1148
88 Overheat Safety Thermostat 30Z1024
94 Hot Air motor Dropper Assy
(39R)
104 Twin Blower Dropper
Resistor (50+39Ω)
N/A
N/A
10C0192
30Z1148
30Z1024
11C0341
11C0323
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 12
PRINCIPAL COMPONENTS
Door and cavity roof
86
72
72
86
67
77
108
114
71
106
107
89
No Description 208V 240V
67 Stirrer glass assy.
( inc. long seals )
71 Door seal kit 11C0292 11C0292
72 Door choke 790007 790007
76 Door Handle Towel Rail 32Z1064 32Z1064
77 Bolt 1/4" 20 UNC 3/4" Hex 109050 109050
86 Cavity roof seal (short) 790052 790052
11C0319 11C0319
109
76
89 Door Handle 40C1020 40C1020
93 Door Assembly 11C0418 11C0418
106 Flat Washer S/S M5 x 20 104036 104036
107 Nylon Washer 104250 104250
108 Spring Washer 31Z5005 31Z5005
109 Flat Washer S/S M6 x 20 104054 104054
114 Nut M4 S/S 31Z4015 31Z4015
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 13
PRINCIPAL COMPONENTS
External Parts and accessories
96
110
99
98
97
No Description 208V 240V
96 Side Panel Left Side 40C1182 40C1182
97 Side Panel Right Side 40C1183 40C1183
98 Top Panel 40C1181 40C1181
99 Foot 32Z1052 32Z1052
100 Wire Rack
Mealstream 501, 503
Mealstream 502
110 Rear Outer Panel 40C1180 40C1180
40C1011
40C1206
40C1011
40C1206
100
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 14
PRINCIPAL COMPONENTS
Electronic Control Panel Assembly
29
34
33
32
31
73
30
No Description 208V 240V
29 On/Off Switch 30Z0503 30Z0503
30
Control Panel Assy with Menukey 11C0379 11C0379
31
Logic Board 11C0377 11C0377
32
Relay Board 11C0402 11C0403
33 AC Ribbon connector ( 6 way ) 11M0116 11M0116
34 DC Ribbon connector ( 10 way ) 11M0360 11M0360
73 MenuKey Assembly 10C0148 10C0148
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 15
PRINCIPAL COMPONENTS
Heater Element and Cavity parts
Mealstream 501
57
68
70
Mealstream 503
57
68
102
102
92
69
85
Mealstream 502
57
68
113
85
92
92
102
112
92
85
92
92
No Description 208V 240V
57 Mesh washer 31Z5044 31Z5044
68 Heater element 40C0949 40C0948
69 Heater element cover plate 790047 790047
70 Baffle 11C0311 11C0311
85 Dome Nut 80X7025 80X7025
92 Tray Support 40C0950 40C0950
102 Hot Air Impeller MC3703B MC3703B
112
113
Element cover plate Assembly
Element cover plate Assembly
Mealstream Ovens Pt. No. 32Z3486 Issue 1
11C0474 11C0474
11C0467 11C0467
Page 16
PRINCIPAL COMPONENTS
( not shown in main views )
54
53
12
Left Hand Door Hinge
Assembly
52
51
55
58
Right Hand Door Hinge
16
52
51
56
Stirrer motor assembly
Assembly
54
53
No. Description All models
12 Door Hinge Assembly LH 11C0167
16 Door Hinge Assembly RH 11C0166
51 Pin 790027
52 Roller 40C0752
53 M5 Hex/hd s/s Screw 101825
54 M5 stainless steel Nut 80X7003
55 LH Hinge bracket 790024
56 RH Hinge bracket 790025
58 Stirrer motor assembly 11C0324
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 17
PRINCIPAL COMPONENTS
Input wiring details
Green/Yellow
6
L1 L2
48 46
Green
47
No Description All models
6 Electrical Supply Terminal Block 31Z0149
46 Cable Gland 31Z0500
47 Gland Nut 31Z0499
48 Electrical Supply Cord 3 Core 30Z1162
91 Electrical Supply Plug 50Amp
(Canada)
Black
31Z0298
White
Hot Air Motor connections and Wiring
208V 60 Hz
L2
L1
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 18
240V 60 Hz
L2
L1
PRINCIPAL COMPONENTS: Part Number Identification Chart 1
No
1 Fuse holder 30Z0231 30Z0231 9
1A Fuse 10 amp 30Z0217 30Z0217 9
2 Fuse holder 30Z0231 30Z0231 9
2A Fuse 10 amp 30Z0217 30Z0217 9
3 Fuse holder 30Z0285 30Z0285 9
3A Fuse 1 amp 30Z0957 30Z0957 9
4 Fuse holder 30Z1178 30Z1178 9
4A Fuse 20 amp 30Z1177 30Z1177 9
5 Fuse holder 30Z1178 30Z1178 9
5A Fuse 20 amp 30Z1177 30Z1177 9
6 Electrical supply terminal block 31Z0149 31Z0149 9/18
7 Filter ( Heater circuit ) 30Z0997 30Z0997 9
8 Filter ( Microwave circuit ) 30Z0997 30Z0997 9
9 Door spring( Long ) 40C1141 40C1141 9
10 Door arm stop assembly 11C0279 11C0279 9
11 Microswitch ( Primary ) 30Z0240 30Z0240 9
12 Door hinge assembly ( LH ) 11C0167 11C0167 9/17
13 Door arm assembly 11C0300 11C0300 9
14 Microswitch ( Monitor ) 30Z0240 30Z0240 9
15 Door arm assembly 11C0300 11C0300 10
16 Door hinge assembly ( RH ) 11C0166 11C0166 10/17
17 Microswitch ( Secondary ) 30Z0240 30Z0240 10
18 Door arm stop assembly 11C0279 11C0279 10
Description
Part No
208V 240V
Page No
20 Steam pipe 40C1023 40C1023 10
21 Steam vent guard 790061 790061 10
22 Temperature sensor 50E123 50E123 10
23 Magnetron 30Z1171 30Z1171 11
24 Resistor 470 R 30Z0283 30Z0283 11
25 HT diode 11C0266 11C0266 11
26 Capacitor 0.88µF (2500V) Kit 30Z0861 30Z0861 11
27 Transformer 30Z1230 30Z1230 11
28 Twin blower motor 30Z1145 30Z1145 11
29 On/Off Switch 30Z0503 30Z0503 15
30 Control Panel Assembly MK US 11C0379 11C0379 15
31 Logic Board 11C0377 11C0377 15
32 Relay Board 11C0402 11C0403 15
33 AC Ribbon connector ( 6 way ) 11M0116 11M0116 15
34 DC Ribbon connector ( 10 way ) 11M0360 11M0360 15
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 19
PRINCIPAL COMPONENTS: Part Number Identification Chart 2
No
46 Cable Gland 31Z0500 31Z0500 18
47 Gland Nut 31Z0499 31Z0499 18
48 Mains Cable 3 Core 30Z1162 30Z1162 18
51 Pin 790027 790027 17
52 Roller 40C0752 40C0752 17
53 M5 Hex/hd s/s Screw 101825 101825 13/17
54 M5 stainless steel Nut 80X7003 80X7003 17
55 LH Hinge bracket 790024 790024 17
56 RH Hinge bracket 790025 790025 17
57 Mesh washer 31Z5044 31Z5044 15
58 Stirrer motor assembly 11C0324 11C0324 17
59 Rubber stop 31Z1150 31Z1150 10
60 25mm OD Flexible conduit 314402 314402 11
61 20mm OD Flexible conduit 314401 314401 11
62 Capacitor clip (99mm) 31Z0176 31Z0176 11
63 Filter 30Z0997 N/A 11
64 Hot air motor service kit 10C0192 10C0192 12
65 Capacitor (Motor starter) 6µF 30Z1148 30Z1148 12
67 Stirrer glass Assy. 11C0319 11C0319 13
68 Heater element 40C0949 40C0948 16
69 Element cover plate Mealstream 501 790047 790047 16
70 Baffle 11C0311 11C0311 16
71 Door seal kit 11C0292 11C0292 13
72 Door choke 790007 790007 13
73 MenuKey Assembly 10C0148 10C0148 15
76 Handle 32Z1064 32Z1064 13
77 Bolt 1/4" 20 UNC 3/4" Hex 109050 109050 16
85 Dome Nut 80X7025 80X7025 13
86 Cavity roof seal (short) 790052 790052 13
87 Magnetron Thermal Trip 2571016 2571016 10
88 Cavity Overheat Thermostat 30Z1024 30Z1024 12
89 Door Handle 40C1020 40C1020 13
90 Cavity Vent Pipe 40C1013 40C1013 10
91 Electrical Supply Plug (50A Canada) 31Z0298 31Z0298 18
92 Tray Support 40C0950 40C0950 16
93 Door Assembly ( bar handle ) 11C0418 11C0418 13
94 Hot Air motor Dropper Assy (39R) N/A 11C0341 12
95 Diode assy with leads 11M0325 11M0325 10
Description
208V 240V
Part No
Page No
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 20
PRINCIPAL COMPONENTS: Part Number Identification Chart 3
No
96 Side Panel Left Side 40C1182 40C1182 14
97 Side Panel Right Side 40C1183 40C1183 14
98 Top Panel 40C1181 40C1181 14
99 Foot 32Z1052 32Z1052 14
100
102 Hot Air Fan MC3703B MC3703B 14
104 Twin Blower Dropper Resistor (50+39Ω) N/A 11C0323 12
106 Flat Washer S/S M5 x 20 104036 104036 13
107 Nylon Washer 104250 104250 13
108 Spring Washer 31Z5005 31Z5005 13
109 Flat Washer S/S M6 x 20 104054 104054 13
110 Door Spacer Kit 10C0171 10C0171 28
111 Rear Outer Panel 40C1180 40C1180 14
112 Element cover plate Assembly 502 11C0474 11C0474 16
113 Element cover plate Assembly 503 11C0467 11C0467 16
114 Nut M4 S/S 31Z4015 31Z4015 13
Wire Shelf, Mealstream 501 & 503 40C1011 40C1011 14
Wire Shelf, Mealstream 502 40C1206 40C1026 14
Description
208V 240V
Part No
Page No
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 21
PROCEDURE FOR MICROWAVE LEAKAGE TEST (1)
Warning
Check for radiation leakage after servicing. Should the leakage be more than 4mW/cm² Inform
Merrychef immediately. After repairing or replacing any radiation safety device, keep a written
record for future reference, as required by D.H.H.S. and Health and Welfare Canada regulation.
This requirement must be strictly observed. In addition, the leakage reading must be recorded on
the service repair documentation while in the customer’s premises.
Please Note
DO NOT attempt to carry out the following procedure
unless you have the following tools.
Tools required for microwave leakage test
600ml glass beaker
Supply of cold water
Microwave leakage meter
Read and understand all of these notes and procedure before carrying out this operation.
Note before measuring.
• Make sure that the survey meter you are using has been calibrated and is suitable for
measuring frequencies of 2,450 MHz.
• Do not exceed meter full scale deflection, leakage meter should initially be set to the
highest scale, then adjusted down as necessary to ensure that low readings are measured
on the most sensitive range.
• To prevent false readings, hold the probe on the grip provided and move along the areas
indicated on the following page. The probe should be moved at 1 inch/second (2.5cm).
• With any casework removed the leakage should not exceed 4mW/cm².
• When measuring the leakage, always hold the probe at 2” (50mm) from the test area using
the probe supplied with the instrument.
• Always hold the probe at right angles to the oven and point of measurement.
Procedure
1 Place 275ml of cold water in the 600ml glass beaker.
2 Place the 600ml glass beaker in the centre of oven.
3 Close the door and set time for 30 seconds then press Power pad 100%
(change water every 30 seconds to prevent boiling).
Set the leakage meter to the appropriate scale/range.
4 Move the survey meter probe along the areas indicated in (Figures 1 to 4 page 23).
5 Remember to change the water after 30 second since water that boils will result in
inaccurate readings.
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 22
PROCEDURE FOR MICROWAVE LEAKAGE TEST (2)
• Readings must be below 4mW/cm². If a level greater that 4mW/cm² is observed,
this should be reported to Garland Service Division immediately.
• In any case, notes should be kept of the leakage that is observed. In terms of level and
position on the oven. This should be kept with the service documentation.
Control Panel - Figure 2
Door Perimeter - Figure 2
Rear and Side Covers - Figure 1, 3 & 4
Left & right Side Air Filters. - Figure 3 & 4
Test for microwave leakage at all points marked with a
Fig. 1
Fig. 3
Fig. 2
Fig. 4
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 23
PROCEDURE FOR POWER OUTPUT MEASUREMENT
The power output specification, 1425W on this model is established under IEC 705 standard
method. This method is only workable in Laboratory controlled conditions.
An approximate method is as follows.
1 Fill one beaker ( glass or plastic ) with one litre ( 1.78 pints ) of tap water
( at about 68ºF/ 20ºC ) and measure the water temperature.
( Use a thermometer with a
2 Place the beaker in the centre of the cavity.
3 Set Time to 1 minute 3 seconds and Power to 100%
Wait until the counter reaches zero.
4 Take the beaker out immediately stir the water with a plastic implement and measure the
water temperature.
5 Calculate the temperature rise of water in the beaker. The temperature rise of the water
should be within the following range:
Temperature Rise
27ºF ( 15ºC ) Minimum
36ºF ( 20ºC ) Maximum
Power Output is affected by the line voltage under load.
For correct Power Output measurement, the line voltage under load must be correct.
1
/10, 0.1 degree gauge ).
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 24
PROCEDURES FOR PRINCIPAL COMPONENTS TEST (1)
1. Power Transformer Test
You will need:
A Digital Multi-meter (D.M.M.)
A Megger or similar resistance meter using 500V d.c.
WARNING: High voltages and large currents are present at the secondary winding
and filament winding of the Power Transformer. It is very dangerous to
work near this part when the oven is on. NEVER make any voltage
measurements at the High Voltage circuits, including the magnetron
filament.
WARNING: Even when the oven is not cooking, the Power Transformer has High
Voltages present because of the Soft Start circuit. Isolate the oven
before testing.
See Safety Code ( Page 4 )
1 Isolate the oven from the mains supply.
2 Ensure that the High Voltage Capacitor is discharged before commencing work.
3 Remove all connections from the Power Transformer.
4 Using a D.M.M., check the resistance of the windings. Results should be as follows:
a Mains winding between tags
b High Voltage winding
c Filament winding
between terminals
5 Using a Megger, test the insulation resistance between:
Primary winding and chassis
Filament winding and chassis
One end of the High Voltage winding is connected to the
chassis, so this is not tested.
Approx. 1.1 Ω
Approx. 60 Ω
Less than 1 Ω
Pass if over 10 MΩ
Pass if over 10 MΩ
a
c
b
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 25
PROCEDURES FOR PRINCIPAL COMPONENTS TEST (2)
2. High Voltage Capacitor Test
You will need:
A Digital Multi-meter (D.M.M.)
A Megger or similar resistance meter using 500V d.c.
WARNING: High voltages and large currents are present at the High Voltage Capacitor.
It is very dangerous to work near this part when the oven is on. NEVER make any voltage
measurements at the High Voltage circuits, including the magnetron filament.
WARNING: Even when the oven is not cooking, the High Voltage Capacitor has High
Voltages present because of the Soft Start circuit. Isolate the oven before testing.
See Safety Code ( Page 4 )
1. Isolate the oven from the mains supply.
2. Ensure that the High Voltage Capacitor is discharged before
commencing work.
3. Remove all connections from the High Voltage Capacitor.
4. Using a D.M.M., check for continuity between the terminals &
compare results with table.
Between Terminals
Pass if approximately 10 MΩ
Between Terminals and Case Pass if open circuit
5. Using a Megger, test the insulation resistance between the
terminals and the case.
Between Terminals and Case
3. High Voltage Rectifier Test
You will need:
Pass if over 100 MΩ
A Megger or similar resistance meter using 500V d.c.
WARNING: High voltages and large currents are present at the High Voltage Rectifier.
It is very dangerous to work near this part when the oven is on. NEVER make any voltage
measurements at the High Voltage circuits, including the magnetron filament .
WARNING: Even when the oven is not cooking, the High Voltage Rectifier has High
Voltages present because of the Soft Start circuit. Isolate the oven before testing.
See Safety Code ( Page 4 )
1. Isolate the oven from the mains supply.
2. Ensure that the High Voltage Capacitor is
discharged before commencing work.
3. Remove all connections from the High Voltage
Rectifier.
4. Using the Megger, test for continuity in both
directions. Compare results with the table.
Open Circuit both ways
Conducts one way only
Short Circuit both ways
Conducts one way, leaks the other
FAIL
PASS
FAIL
FAIL
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 26
PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST (1)
The door on the Mealstream oven is monitored by three microswitches. These are used in the
conventional “Primary, Secondary and Monitor” switch arrangement shown below.
The switches operate as follows:
Door Interlock Arrangement
Switches shown in Door Closed position
L1
Power In
L2
1. Monitor switch ( 14 ,Top left-hand Side ). The Monitor switch will produce
a short circuit across the mains supply if the Primary interlock switch is
faulty, when the door is opened, thus blowing the microwave fuse and
rendering the oven inoperative.
2. Primary Interlock ( 11 , Bottom left-hand ) and Secondary Interlock
( 17 , Bottom right-hand ) Switches. Operate simultaneously.
The Primary switch will cut off the microwave emissions from the oven when
the door is opened by breaking the electrical supply circuit to the
transformers. The Secondary interlock switch will cut off the microwave
emission if the Primary switch have failed.
Note:
If operation of the Monitor switch has caused the Microwave Fuse to blow,
the Primary and Monitor microswitches must be changed, as they may have
been damaged by the high short-circuit currents involved.
Primary switch
11
17 Secondary switch
Power Out
14 Monitor switch
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 27
PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST (2)
Please Note
DO NOT attempt to carry out the following procedure
unless you have the following tools and parts.
Continuity Meter
Door Spacer Kit
Part No. 10C0171
Spacer No. required Part No.
S10 Door Spacer 10mm
S5 Door Spacer 5mm
S1 Door Spacer 1mm
2 40C1119
2 40C1118
2 40C1114
WARNING
Before starting this test procedure please make sure that the oven is disconnected
from the electrical supply and that the oven power switch (ON/OFF) is in the OFF
position.
After each step check that the interlocks are operating in the correct order using a
continuity meter.
See Safety Code ( Page 4 )
Disconnect the microswitches and check for the continuity of the switches with a continuity meter
Step 1: Set the interlock so that they activate in the following order.
When closing the door.
Interlock Order
SW1 (Monitor) 1st
SW2 (Primary) 2
SW3 (Secondary) 2
When opening the door.
Interlock Order
SW1 (Monitor) 3rd
SW2 (Primary) 1
SW3 (Secondary) 1
nd
Note both SW2 and SW3 activate together
nd
Note both SW2 and SW3 activate together
st
Note both SW2 and SW3 activate together
st
Note both SW2 and SW3 activate together
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 28
PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST (3)
Step 2: Insert S10 10mm spacer into door.
(See figure 1 below for inserting spacer
correctly).
Step 3: Remove S10 10mm spacer and insert S1 1mm
spacer into the door and close the door.
Step 4: Remove S1 1mm spacer and insert S5 5mm
spacer into the door and close the door.
If an oven fails this sequence
then check the microswitches are functioning
Interlock Order
SW1 (Monitor) CLOSED
SW2 (Primary) OPEN
SW3 (Secondary) OPEN
Interlock Order
SW1 (Monitor) OPEN
SW2 (Primary) CLOSED
SW3 (Secondary) CLOSED
Interlock Order
SW1 (Monitor) OPEN
SW2 (Primary) OPEN
SW3 (Secondary) OPEN
correctly and repeat steps 1 to 4.
After carrying out this procedure make sure that the interlock monitor switch is properly connected
according to the circuit diagram on pages 44-46.
Figure 1
Door side seal
Door top seal
Door spacer
The door spacer must always be
located on the point where the side
seals and top seals meet.
Please note.
It is very important after completing this procedure to carry out a
microwave leakage test procedure. See pages 22-23.
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 29
PROCEDURE FOR BUILDING AND FITTING MEALSTREAM DOOR
Parts required for door fitting
Please Note
DO NOT attempt to carry out the following procedure
unless you have the following tools and parts.
Item No. Description Part No. Quantity
1 RHS door hinge assy 11C0166 1
2 M5 x 10mm 101820 4
3 M5 flat washer 31Z5008 29
4 M5 shake proof washer 31Z5012 29
5 Spacer 790084 2
6 M5 x 16mm hex screw 101876 2
7 Door frame assy 11C0303 1
8 LHS door hinge assy 11C0167 1
9 Door arm assy 11C0300 2
10 Door arm Pivot Pin 790010 2
11 Door spring 40C1141 2
12 Door Stop 40C0854 2
13 Door stop spring clip 31Z5047 2
14 M5 stainless steel full nut 80X07003 23
15 Door seal set of 4 11C0292 1
16 CAF 30 Adhesive 31Z0186 As required
17 Door insulation set 40C0942 1
18 Outer Door Skin Check Oven Model 1
19 M3 counter sunk screw 31Z3094 7
20 Choke Plate 790007 1
21 DOOR SPACER KIT 10C0171 1
Tools required for door fitting
M5 Nut runner Door Spacers S325 & 3 off S215
Flat head screw driver Long nose pliers
5mm open-ended spanner Adhesive skeleton gun
Engineers rule
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 30
PROCEDURE FOR BUILDING AND FITTING MEALSTREAM DOOR
1. Visually check all parts to be used.
2. Fit right hand side (RHS) Hinge assy. to base
assy. loosely fit in place with bottom bolts, 2
off M5 x 10mm, 2 off M5 flat washer, 2 off M5
shockproof washer.
Fit a spacer to fill gap between Hinge assy
and Inner side panel, loosely fit spacer in
place with 1 off M5 bolt x 16mm, 1 off M5 flat
washer, 1 off M5 shakeproof washer.
3. Insert (RHS) Pivot pin of door frame into
(RHS) Hinge assy. Place door frame against
cavity face and slide on (LHS) Hinge assy to
the (LHS) Pivot pin of door frame,
Spacer
Hinge
fixings
Pivot
pin
4. Fit Left hand side (LHS) Hinge assy to base
assy, loosely fit in place with bottom bolts, 2
off M5 x 10mm, 2 off M5 flat washer, 2 off M5
shockproof washer. Fit spacer to fill gap
between Hinge assy. and Inner side panel,
loosely fit spacer in place with 1 off M5 bolt x
16mm, 1 off M5 flat washer, 1 off M5
shakeproof washer.
5. With the door frame held firmly against cavity
tighten fixing bolts to secure (RHS) and (LHS)
Hinge Assy to base.
Note:
Do not tighten bolt securing hinge to inner
side panel.
Pivot pin
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 31
Hinge
PROCEDURE FOR BUILDING AND FITTING MEALSTREAM DOOR
6. Fit (RHS) and (LHS) door arm assemblies through
slots in cavity and insert door arm pivot pins
through door arms into door frame.
Door arm pivot pin
7. Ensure the door frame is fitted central by using
the following method:
Measure the distance between the side of the door
and the edge of the pin location hole on each side
with the door in the closed position.
Add these two measurements together and divide
by 2.
Adjust hinge adjustment bolt so that the door is
the distance calculated from the side of the door
to the edge of the pin location hole and lock in
position with lock nut.
Edge of pin
location hole
Door hinge adjustment
Door
8. With both door arms fitted and the door in the
open position, check the door is level and if
necessary apply gentle pressure down on door to
level door. Tighten the top securing bolts on
(LHS) & (RHS) hinges while holding door down.
9. Fit door springs to door arms and to the hook at
base of inner side panels.
Check operation of door and remove both springs.
Gentle
downward
pressure
Secure
bolt
Spring clips
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 32
PROCEDURE FOR BUILDING AND FITTING MEALSTREAM DOOR
10. Fit door shim plate Pt. No. 40C1084.
Position door choke to door frame assy
making sure it is in the correct orientation
(the top of door choke is marked with ‘T‘ on
the underside).
11. Loosely fit the choke plate in the three central
locations using M5 full nut, M5 Ext Shake-proof
washer, 3x M5 plain washer ensure that the studs
are central in the holes in the shim plate and door
choke plate.
12. To set the position of the door choke plate
tape choke spacer S325 to the cavity base
( A ) and choke spacers S215 to the top
and each side of the door choke ( B, C &
D )
C
‘T’
Mark
Stage 1
Stage 2
A
B
Close the door and centralise the door
choke. Push down on the choke plate and
secure the three central locations
( shown in yellow in diagram )
Fit the remaining studs with 20x M5 Magnuts and tighten fixings evenly.
Note: See diagram for recommended
tightening sequence.
13. Remove spacing pieces and check door
operation.
D
A
B
C
D
Cavity base
Choke fingers Right
Choke fingers Left
Choke fingers top
10 6 2 1st 5 9 13
16 14
12 8 4 1st 3 7 11
Yellow are tightened at setup of choke,
green are tightened after initial setup
and the remaining nuts are tightened in
numerical order.
17 15
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 33
PROCEDURE FOR BUILDING AND FITTING MEALSTREAM DOOR
12. Fold the square piece oven insulation in half
and place it in the recess in the oven door.
Place the rectangular piece into the remainder
of the door (foil facing out).
13. Place the outer skin over the door frame
assembly and fix around the LHS, RHS & top
using 7 of M3x12 counter sunk screws around
the LHS, RHS and top of the door.
Squeeze skin onto door frame before
tightening up screws to ensure snug fit.
See matrix below for door skin assembly
to be used.
Grease up door arms where contact is made
with roller.
Please note.
It is very important after completing this procedure,
to carry out a Door interlock adjustment and test procedure.
See pages 27-29.
Stage 1
Stage 2
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 34
PROCEDURE FOR REPLACING DOOR SEAL ASSEMBLY (1)
Parts required for replacing carbon loaded door seals
Please Note
DO NOT attempt to carry out the following procedure
unless you have the following tools and parts.
Item Description Part Number Quantity
1 Door seal set of 4 11C0292 1
2 CAF 30 ( Black ) 31Z0186 As required
Tools required for replacing carbon loaded door seals
Long nose pliers
Adhesive skeleton gun
Flat head screw driver
Please note.
Before proceeding with this procedure ensure that the oven is disconnected
from the power supply.
If the oven has been operating recently please allow time for the oven to cool.
Removing Door seal
1 Open the oven door.
2 Use a pair of long nose pliers to unclip one end of the seal. (See figure 1 page 36)
3 Peel back the door seal assembly and unclip at the other end. (See figure 2 page 36)
4 Remove the residue CAF 30 adhesive with a flat head screw driver. (See figure 3 page 36)
5 Visually inspect the vitreous enamel to ensure that it is undamaged.
Fitting a New Seal
1 Clip on end of the door seal in place. Using a pair of long nose pliers, stretch the door seal
and connect the other end in place. (See figure 4, 5 & 6 page 36)
2 Visually inspect that the door seal is sitting in the rebate provided.
3* Perform door interlock set-up procedure (See page 27-29)
4* Perform a microwave leakage test procedure. (See page 22-23)
5 Lift the seal and applied a thin line of CAF 30 adhesive along the length of the rebate and
push the seal down. (See figure 7 page 36)
6 Seal the ends of the door seal with CAF 30 (See figure 8 page 36)
Leave the door in the open position to allow the adhesive to set.
* It is very important to carry out these procedures
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 35
PROCEDURE FOR REPLACING DOOR SEAL ASSEMBLY (2)
Figure 1
Figure 3
Figure 2
Figure 4
Figure 5
Figure 7
Figure 6
Figure 8
Please note.
It is very important after completing this procedure,
to do a Door interlock adjustment and test procedure.
See pages 27-29.
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 36
PROCEDURE FOR REMOVING SHELF RUNNERS AND ELEMENT COVER PLATE
Please Note
DO NOT attempt to carry out the following procedure
unless you have the following tools.
Tools required for removing shelf runners and element cover plate.
M6 nut runner
M5 nut runner
M6 x 12mm
stainless steel Hex
Head screw
Pt No. 80T7133
Shelf runner
1. Loosen the rear fixings screws of both shelf runners with M6 nut runner.
2. Remove the front fixings screws of both shelf runners with M6 nut runner.
3. Pull the shelf runners forwards away from the rear screws.
4. Remove the 4 off M5 dome nut securing the Element cover plate.
5. Lift the Element cover plate out taking care to not damage the temperature sensor pocket.
M5 stainless steel
dome nut
Pt. No. 80X7025
Element cover plate
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 37
PROCEDURE FOR REPLACING HEATER ELEMENT
Please Note
DO NOT attempt to carry out the following procedure
unless you have the following part and tools.
Parts required for replacing heater element.
Item Description Part Number Quantity
1 Heater Element 208 volt 40C0949 / 240 volt 40C0948 1
2 Mesh Washer 31Z5044 3
Tools required for replacing heater element.
M5 nut runner
1. Disconnect or isolate oven from mains supply.
2. Remove outer covers.
3. Remove shelf runners and element cover plate
( See page 37 ).
4. Disconnect wires from heater element terminals at rear of
oven.
5. Remove M5 screw securing heater element.
6. Remove heater element.
7. Refit new heater element with new mesh
washers fitted over each terminal and 3 off
M5 Flat washer over the M5 screw (this is
very important to prevent microwave
leakage).
8. Tighten M5 screw and check that the
heater element is not touching the
cavity or protruding to much that it
will not touch the element cover plate.
9. Reconnect wires to heater element terminals
at rear of oven.
10. Replace element cover plate and shelf runners.
11. Perform Microwave Leakage procedure
(see page 22-23) checking carefully around
the heater element terminals at rear of oven.
12. Replace outer covers and fully test oven.
Heater Element
M5 x 25mm Hex head
S/S screw Pt. No. 101825
3x M5 Flat
Washers
Mesh
Washers
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 38
PROCEDURE FOR REPLACING HOT AIR MOTOR ASSEMBLY
Please Note
DO NOT attempt to carry out the following procedure
unless you have the following part and tools.
Parts required for replacing hot air motor assembly.
Item Description Part Number Quantity
1 Hot Air Motor Service Kit 10C0192 1
Tools required for replacing hot air motor assembly.
M5 nut runner
1. Disconnect or isolate Oven from mains supply.
2. Remove outer covers.
3. Remove shelf runners and element cover plate (See page 37).
4. Looen fan blade Allen screw and remove fan blade.
5. Disconnect motor connection at terminal block.
(Note: which wire colour goes to which terminal).
6. Disconnect Motor Earth tag then undo all securing nuts from the
motor mounting plate and remove the fan motor assembly.
7. Fit new hot air motor assembly, and fit all securing washers and
nuts, ensure it is aligned centrally into the hole in the cavity, and
tighten all securing nuts. Make sure the ground wire is connected.
8. Reconnect motor connection at terminal block.
(Note: correct position of each wire colour).
9. Refit fan blade and tighten fan blade Allen screw, and ensure that
the fan/motor rotates free by hand.
10. Refit shelf runners and element cover plate.
11. Perform Microwave Leakage procedure (see pages 22-23),
checking carefully around the hot air motor assembly at rear
of oven.
12. Replace outer covers and fully test oven.
Fan blade
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 39
PROCEDURE FOR REPLACING MAGNETRON ASSEMBLY (1)
Parts required for replacing magnetron
Please Note
DO NOT attempt to carry out the following procedure
unless you have the following tools and parts.
Item Description Part Number Quantity
1 Magnetron 30Z1171 1
Tools required for replacing magnetron
Philips screw driver
M5 nut runner
WARNING
Before proceeding with this procedure ensure that the oven
is disconnected from the power supply,
And the high voltage capacitors are discharged
See Safety Code ( Page 4 )
1. Remove the top and side casing from the oven.
2. Remove the air duct cover plate.
(See figure 1 page 41)
3. Disconnect the 2 wires and earth wire from the over temperature stat and the 3 wires from
the magnetron connection block.
(See figure 2 page 41)
4. Remove the 4 nuts from the magnetron fixing.
(See figure 3 page 41)
5. Remove the magnetron.
(See figure 4 page 41)
6. Remove the 2 screws form the over temperature stat on the magnetron and remove.
(See figure 4 page 41)
7. Visually inspect the new magnetron making sure that the wire mesh gasket seal is in place
and undamaged. Check the outer casing for any damage such as dents.
(See figure 5 page 41)
8. Attach the oven temperature stat to the new magnetron.
(See figure 5 page 41)
9. Visually inspect the magnetron mount in the wave guide making sure that it is undamaged
and that there is no debris that may obstruct the new magnetron when fitted.
(See figure 5 page 41)
10. Place the new magnetron in position making sure it is in the correct orientation.
11. Replace the 4 fixing nuts making sure that they are tightened equally.
12. Reconnect the wiring to the over temperature stat.
13. Reconnect the wiring to the magnetron.
14. Replace the air duct cover.
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 40
PROCEDURE FOR REPLACING MAGNETRON ASSEMBLY (2)
Figure 1 - 6
Figure 1
Screw
Figure 3
Temperature
Stat.
Figure 2
Temperature
Stat.
Figure 4
Magnetron
connection
block
4 x Magnetron
screw fixings
Figure 5 Figure 6
Temperature
Stat.
Screws
Wire mesh
Magnetron mount
Please note.
After completing this procedure do a microwave leakage test.
See page 22-23.
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 41
PROCEDURE FOR TESTING MEMBRANE PANEL CIRCUIT
You will need:
A Digital Multi-meter (D.M.M.)
1. The oven isolate from the electrical supply.
2. Remove the Logic Assembly from the Control Panel Housing.
3. Unplug the membrane “tail” from the Logic PCB Assembly.
4. Using a D.M.M., check for continuity between the correct terminals when the pads are
pressed.
5. When the panel has been tested, re-assemble and re-test the control circuit.
1 10
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 42
Page 43
CIRCUIT DIAGRAM: ALL MODELS
Mealstream Ovens Pt. No. 32Z3486 Issue 1
ERROR CODES AND DIAGNOSTICS
The Mealstream will identify some of the most common problems by flashing an error message
code in the time display window.
These are the error messages, and suggestions for repairing them.
Error Message
1
1
1 Oven Cavity overheating Check cavity sensor
Possible Cause Service
Door not fully shut
2
Possible electrical fault
No time has been set
Invalid time has been set
2
Invalid program has been set
3
Number pad failure
4
Memory Failure running a
5
Program
Oven not heating up
1
Possible Heater circuit fault
2
Close door fully
Check Microswitch Door Circuit
Check Microswitch Connection to PCB
Check Ribbon Cable
Check Relay PCB & Logic PCB
Set a time
Set a valid time
Use call-back to check program
(MenuKey: no key downloaded)
Membrane key short circuit
Re-Program Pad,
if fault repeats replace Logic PCB
Check heater fuse
Confirm operation of heater, overheat
stat and heater circuit
Confirm heater relay is operating
1 Oven is not at correct
temperature to start program
Operator Error !!
1 Oven control area is
overheating.
MenuKey removed before the
download is complete
or the process has been interrupted.
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 44
Allow oven to reach correct
Programmed temperature
Check air filters
Check axial fan
Check installation for hot air intake
Switch oven off and begin the MenuKey
download again. (see Appendix 2 )
APPENDIX 1: Cleaning procedure Mealstream 501
For the oven to operate at peak efficiency, the cavity, door and the air filters 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 efficiency of your oven.
Follow the SAFETY INSTRUCTIONS at the beginning of this manual.
• ALWAYS switch off at the electrical supply and allow
oven to cool for at least 20 minutes before cleaning.
• As required, wipe out spillage's with disposable paper
wipes
• NEVER use steel wool, knives or harsh abrasives on
any part of the oven
As with all electrical appliances, it is wise to have the
electrical connections inspected periodically.
Cleaning the Air Filters
1 Remove the air filters from each side of the oven by
sliding the filter out from the front.
2 Wash in clean, warm soapy water, rinse and pat dry. Slide
back into position through slots.
Cleaning the oven cavity and door
1 Remove food particles from the gap between the rear
baffle plate and the floor of the oven with a clean, dry
brush. ( Location A )
Remove food particles from between the inside edge of
the door and the front of the oven floor using a clean, dry
brush. ( Location B )
2 Apply non-caustic oven cleaner to interior surfaces
except door seals. Leave for the recommended time.
Wash off using a clean cloth and plenty of clean, warm
water. Dry using a fresh, clean cloth.
3 Wipe hinges with a clean, damp cloth.
DO NOT apply lubricating oil.
4 Wipe door seals carefully with a clean damp cloth.
Examine for signs of wear or damage.
Faults arising from neglect
or misuse including use
without clean filters in place
are not covered by the
guarantee. Service visits as
a result of such faults will be
chargeable.
DO NOT USE THE OVEN
WITHOUT CLEAN AIR
FILTERS IN POSITION
B
A
Door Seal
Cleaning the control panel and exterior surfaces
Wipe down regularly with a damp cloth.
Hints and Tips for stubborn stains in the oven cavity
1 Switch on oven with microwave power only (without heat).
2 Place a container of water (1.5 litres) into the centre of the
oven cavity.
3 Set microwave power to 100%.
4 Set timer to 30 minutes and press start button at end of
steam cycle wipe out cavity with a clean cloth.
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 45
If the door seals are damaged,
the oven must be repaired by an
approved Servicer.
APPENDIX 1: Cleaning procedure Mealstream 502, Mealstream 503
For the oven to operate at peak efficiency, the cavity, door and the air filters 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 efficiency of your oven.
Follow the SAFETY INSTRUCTIONS at the beginning of this manual.
• ALWAYS switch off at the electrical supply and allow
oven to cool for at least 20 minutes before cleaning.
• As required, wipe out spillage's with disposable paper
wipes
• NEVER use steel wool, knives or harsh abrasives on
any part of the oven
As with all electrical appliances, it is wise to have the
electrical connections inspected periodically.
Cleaning the Air Filters
1 Remove the air filters from each side of the oven by
sliding the filter out from the front.
2 Wash in clean, warm soapy water, rinse and pat dry. Slide
back into position through slots.
Cleaning the oven cavity and door
1 Remove food particles from the gap between the rear
baffle plate and the floor of the oven with a clean, dry
brush. ( Location A )
Remove food particles from between the inside edge of
the door and the front of the oven floor using a clean, dry
brush. ( Location B )
Do not spray any cleaning fluid
directly into the cavity filter
2 Apply non-caustic oven cleaner to interior surfaces except
door seals. Leave for the recommended time. Wash off
using a clean cloth and plenty of clean, warm water. Dry
using a fresh, clean cloth.
3 Wipe hinges with a clean, damp cloth.
DO NOT apply lubricating oil.
4 Wipe door seals carefully with a clean damp cloth.
Examine for signs of wear or damage.
Faults arising from neglect
or misuse including use
without clean filters in place
are not covered by the
guarantee. Service visits as
a result of such faults will be
chargeable.
DO NOT USE THE OVEN
WITHOUT CLEAN AIR
FILTERS IN POSITION
A
Door Seal
B
Cleaning the control panel and exterior surfaces
Wipe down regularly with a damp cloth.
Hints and Tips for stubborn stains in the oven cavity
1 Switch on oven with microwave power only (without heat).
2 Place a container of water (1.5 litres) into the centre of the
oven cavity.
3 Set microwave power to 100%.
4 Set timer to 30 minutes and press start button at end of
steam cycle wipe out cavity with a clean cloth.
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 46
If the door seals are damaged,
the oven must be repaired by an
approved Servicer.
APPENDIX 2: MenuKey™ DOWNLOAD PROCEDURE
The MenuKey™ System automatically changes all the
cooking programs on the numbered icon pads with the
turn of a key.
To change the menus on the oven:
Ensure the power switch is off.
1
Lift the MenuKey™ cover in the top panel
2
of the oven and put the key in the keyhole
Turn the key clockwise to the stop
( ¼ turn ).
Do not remove the key at this stage.
3
Switch the power switch on.
The oven will now go through the program
download sequence by displaying the
following:
The Key Code
The number of
programs and each
program number on the key.
When the display shows 0:00, the cavity
lights up and the fans start.
Remove the key and close the cover and
the oven is ready to use with the new
programs.
To confirm the download is successful
Switch off the oven.
Switch on and the display briefly will show the following:
1. The new key code
2. 0:00 (oven ready to use)
example: Key 01
example: 38 programs
EPS-FAIL-REDO
If the key is removed before
the download is complete or
the process is interupted the
display shows EPS then FAIL
then REDO
Switch oven off and begin the
MenuKey download again.
Mealstream Ovens Pt. No. 32Z3486 Issue 1
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APPENDIX 3: TEMPERATURE SENSOR RESISTANCE DATA
Temperature Sensor Resistance
Temp °F Temp °C Min. Rate
kΩ
212 100 11.490 13.060 14.810
302 150 2.803 3.161 3.434
392 200 0.950 1.000 1.050
482 250 0.3572 0.3865 0.4171
Standard
Rate kΩ
Max. Rate
kΩ
R(200)°C = 1 kΩ ± 5%
Note:
These resistances will only be apparent in a stable cavity temperature as the
sensor has a slow response time.
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 48
APPENDIX 4: RECOMMENDED SPARES LIST
Recommended spares list (to support 1– 3 ovens)
Available as a complete kit (208V & 240V 60Hz) part number 10C0234
Part No. Description
11C0292 DOOR SEAL KIT 208V & 240V 1
11C0319 STIRRER GLASS ASSY (Cavity roof ) 208V & 240V 1
11C0323 RESISTOR DROP 50+39R US 240V 1
11C0324 STIRRER MOTOR ASSY 208V & 240V 1
11C0341 RESISTOR DROP 39R US 240V 1
11C0377 LOGIC BOARD 208V & 240V 1
11C0402 RELAY BOARD 208V 208V 1
11C0403 RELAY BOARD 240V 240V 1
30Z1171 MAGNETRON PANASONIC 208V & 240V 2
10C0192 HOT AIR MOTOR SERVICE KIT 208V & 240V 1
30Z0217 FUSE 10A HRC 208V & 240V 4
30Z0231 FUSEHOLDER ( 1in 13A) 208V & 240V 3
30Z0240 MICROSWITCH V5A010CB1N 208V & 240V 6
30Z0283 RESISTOR 470R 50W 208V & 240V 1
30Z0503 ON/OFF SWITCH 208V & 240V 1
30Z0957 FUSE 1A (1x1/4in HBC ) 208V & 240V 1
30Z0997 FILTER 16A 208V & 240V 4
30Z1145 TWIN BLOWER MOTOR 208V & 240V 1
30Z1148 MOTOR START CAP 6uF 208V & 240V 1
30Z1177 FUSE 20 AMP 208V & 240V 20
30Z1178 FUSE HOLDER 30A 208V & 240V 4
30Z1230 TRANSFORMER MULTI 208 220 240 60HZ 208V 2
790052 SILICONE SEAL for roof of cavity 208V & 240V 3 metres
2571016 Magnetron thermal trip 208V & 240V 2
10C0171 Door spacer tools kit 208V & 240V 1
11M0325 Diode Assy with leads 208V & 240V 2
11C0379 Control panel Assy MK US 208V & 240V 1
11M0116 AC ribbon connector ( 6 way ) 208V & 240V 1
11M0360 AC ribbon connector ( 10 way ) 208V & 240V 1
30Z1024 Cavity overheat thermostat 208V & 240V 1
40C1141 Door spring large 208V & 240V 2
50E123 Temperature sensor 208V & 240V 1
30Z0861 Capacitor 0.88uF 2500V 208V & 240V 2
40C0948 Heater element 3.0kW 240V 240V 1
40C0949 Heater element 3.0kW 208V 208V 1
Supply
Voltage (60Hz)
Quantity
per kit
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 49
MANUAL CORRECTIONS AND MODIFICATIONS
Whilst every effort has been made to ensure that the information contained in this manual is
accurate and complete, if you believe that an error has been made, or if you have any
suggestions for how the manual could be improved, please fill in and return this form. A review of
any forms returned will be made on a regular basis, and the manual will be updated if required.
Name
Address
Page number on which error occurs (if applicable) - Mealstream US
Description of error
Suggestion for improvement to manual
Please return this form to: Engineering Department
Merrychef Ltd
Station Road West
Ash Vale
Aldershot
Hampshire GU12 5XA
United Kingdom
Or Fax it on:
+44 (0) 1252 371007
Mealstream Ovens Pt. No. 32Z3486 Issue 1
Page 50
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