Merrychef Mealstream Service Manual
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
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