Merrychef Mealstream 400 Service Manual

Page 1
Page 1 400 Series Ovens 32Z3769 Issue 1
CAUTION MICROWAVE EMISSIONS
DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE
GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY
SERVICE MANUAL
Mealstream 400
For all 400 Series models manufactured from February 2009
Part No. 32Z3769 Issue No. 1
SERIES
Merr ychef
Page 2
Page 2 400 Series Ovens 32Z3769 Issue 1
Merrychef Limited, Station Road West, Ash Vale, Aldershot Hampshire GU12 5XA United Kingdom
Tel: +44 (0)1252 371000 Fax: +44 (0)1252 371007 Internet address: http://www.merrychef.com
E-mail: sales@merrychef.com or service@merrychef.com
Table of Contents
Safety Code ...................................................................................................3
Product Specifications ................................................................................... 4
Installation Instructions ..................................................................................5
Electrical Installation ......................................................................................6
Error Codes and Diagnostics.........................................................................7
Main Features................................................................................................8
Electronic Controls.........................................................................................9
Power Output Testing to EN 60335-2-90.....................................................10
Power Transformer Test ..............................................................................10
High Voltage Capacitor Test........................................................................11
High Voltage Rectifier Test ..........................................................................11
Magnetron Test............................................................................................11
Door Interlock Operation........................................................................ 12-14
Casework.....................................................................................................15
Door Mechanism..........................................................................................16
Oven Cavity Components & Hot Air System ...............................................17
Oven Door Assembly ...................................................................................18
Door Interlock RHS, Magnetron & Stirrer motor ..........................................19
Principal components LHS & Rear View .....................................................20
Principal components RHS 1: Models _EE5, _XE5 [CD2] ..........................21
Principal components RHS 2: Models _EE5, _XE5 [CD2] ..........................22
Principal components RHS 3: Models _XX5, _XX52...................................23
Input Wiring, Filters and Fuses 1 .................................................................24
Input Wiring, Filters and Fuses 2 .................................................................25
Control Panel 1: Electronic Controls............................................................26
Control Panel 2: Membrane Panel circuit ....................................................27
Control Panel 3: Manual Control assembly .................................................28
Part No. Identification ........................................................................... 29-30
Appendix 1 MenuKey Download Procedure ................................................31
Appendix 2 Cleaning Procedure ..................................................................32
Recommended Parts List (Spares)........................................................34334
Circuit Diagrams .................................................................................... 35-38
Merrychef and MenuKey™ are registered Trademarks of Merrychef Ltd.
For Service contact:
Page 3
Page 3 400 Series Ovens 32Z3769 Issue 1
This manual is designed to assist engineers who have been on a recognised product familiarisation and training course run by Merrychef Limited. It has been prepared to offer technical guidance for the Merrychef Mealstream 400 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 the rear cover from the oven ensure you do 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 Electrical Supply.
Upon completion of a service on a Mealstream 401/403 oven, or before reconnecting the appliance to the mains supply for testing, check all of the following points:
All internal electrical connections are correct.
All wiring insulation is correct and is not touching a sharp edge.
All Earth connections are electrically and mechanically secure.
All four 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 four of the door interlock switches in the correct order.
All fuse-holder safety covers are correctly fitted.
The temperature sensor is correctly connected to the Power PCB.
Before finishing the service call, recheck the following points:
All of the electronics are functioning correctly, and all of the touch pads are working.
The turntable is rotating correctly.
The power output of the oven is correct (see pages 12 & 13 ).
Microwave emission is below permissible limit - 5 mW/cm² (see BS EN 60335-2-90).
Oven has correct 50mm air gap all round and 150mm above.
Air flow should not be restricted.
SAFETY CODE
Page 4
Page 4 400 Series Ovens 32Z3769 Issue 1
Power Requirements
See RATING PLATE on rear of oven
Power Output (IEC 705)
Microwave 100% Convection Combination
700W (_EE, _XE) 3000W (_XX5 ) 700W + 1500W ( _EE ) 700W + 3000W ( _XE ) 1000W + 3000W ( _XX5 )
External Dimensions
Height Width Depth
530 mm (Plus 150 mm minimum clearance above) 550 mm (Plus 50 mm minimum clearance each side) 575 mm (Plus 50 mm clearance behind)
Internal Dimensions
Height Width Depth Turntable Capacity
315 mm 330 mm 330 mm 300 mm Diameter
34.3 litres
Weight Nett
Gross packed
All models except XX5 45kg, XX5 55kg All models except XX5 58kg, XX5 68kg
Construction Cavity
Casework
Stainless Steel 304 Stainless Steel Anodised Aluminium Extrusions
Settings Microwave
Temperature Timer
100%,75%,50%,25%, Convection only Off, 175°C, 200°C, 225°C, 250°C, 275°C Up to 30 minutes
Up to 3 cooking stages of up to 30 minutes each (Programmed)
Model No.: 1003 + Voltage + Frequency + Current + Controls
Model prefix
Voltage
Frequency
Current Control
Type
2 = 220-230V a.c. 4 = 230-240V a.c.
5 = 50 Hz 6 = 60 Hz
EE = 13A 5 =
Series 5
controls
1003
XE = 30A XX = 30A
Supply
Phase
2=
Twin
Phase
MenuKey
MK
Catalytic
converter*
C
ELECTRONIC CONTROLS: ( EC401 & EC403 models )
Model No.: 1003 + Voltage + Frequency + Current
Model prefix Voltage Frequency Current
1003
2 = 220-230V a.c. 4 = 230-240V a.c.
5 = 50 Hz 6 = 60 Hz
CD2 = 13amp XD2 = 30amp
MANUAL CONTROLS ( CD & XD models )
For example: 100345XE52MK
230-240V, 50Hz, 30A, Series 5 Controls, Twin Phase, MenuKey
Product specifications: Mealstream 401 & 403 models
+ Phase + MenuKey + Catalytic converter
* A Catalytic converter is fitted to Mealstream 403 models only
Page 5
Page 5 400 Series Ovens 32Z3769 Issue 1
Positioning the Oven
In order to maintain adequate ventilation for air intake and exhaust, and to allow access for cleaning the air filters, you must allow a minimum of 50mm(2 inches) clearance at the sides and rear of the oven, and at least 150mm above. Air intake temperature should not exceed 35°C (95°F). Excessive temperature will lead to reduced operating duty cycle or premature ageing of internal components.
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. ALWAYS Place containers in the cavity carefully - impact damage may chip the
vitreous enamel coating.
Installation instructions
Page 6
Page 6 400 Series Ovens 32Z3769 Issue 1
Models 1003__XE52, 1003__XX52
WARNING
All models ( 30A ) must be connected to a separate electrical supply rated at 30 Amps by a qualified and approved electrician. A suitable 30 amp rated isolating switch with a 3mm contact gap on both poles should be fitted for each oven installed.
Establishments with standard ( Type ‘B’ ) circuit breakers are sensitive to ‘surges’ which occur on switching on freezers, refrigerators and other catering equipment, including microwave ovens. Because of this, we strongly recommend that a separate Type ‘C’ circuit breaker ( designed specifically for this type of equipment ) must be fitted. An individual, suitably rated circuit breaker should be fitted for each oven installed.
TWIN PHASE
The Mealstream 401 oven Twin Phase models should be connected as shown in Diagram 2. The Circuit Breaker should be rated at 20A per phase (TypeC).
Electrical installation:
WARNING: This appliance must be earthed.
Failure to do so may result in electric shock and death
Where an approved and fitted moulded plug is supplied we strongly recommend that this plug is never removed. However certain establishments may require a different plug to be fitted. In this case, the wiring instructions shown should be observed.
Models 1003__EE5, 1003__CD2 The power outlet used must be individually fused. It is essential that the socket is properly installed and earthed. It should be fed from a circuit which is suitable for high power electrical appliances and it is important that this circuit is not overloaded.
Models 1003__XE5, 1003__XD, 1003__XX5 When supplied, single phase models are fitted with a Blue 32Amp Plug approved to BS4343. Wiring cable colours as shown in Diagram 1
The Circuit Breaker should be rated at 45A (TypeC).
Diagram 1
Diagram 2
Simplified loading Diagram
Page 7
Page 7 400 Series Ovens 32Z3769 Issue 1
Error codes and diagnostics
Electronic Control Models The control panel will identify some of the most common problems by flashing an error message code in the time display window.
Error Message
Possible Cause Service
1
2
Door not fully shut
Possible electrical fault
Close door fully.
Check Microswitch Door Circuit Check Microswitch Connection to PCB Check Ribbon Cable Check Relay PCB & Logic PCB
1 2 3 4
5
No time has been set Invalid time has been set Invalid program has been set Number pad failure
Memory Failure running a Program
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
1 Oven is not at correct temperature
to start program
Allow oven to reach correct Programmed temperature
1 MenuKey removed before the
download is complete or the process has been interrupted
Switch oven off and begin the MenuKey download again
1 Magnetron overheated Air inlet on rear of machine being obstructed.
High air inlet temperature. Slow running cooling fan, jammed turntable or broken gearbox (cooling fan also drives turntable _XE5 models) Faulty magnetron overheat ‘stat or associated wiring.
1 Jumper installed incorrectly on
PCB logic board
Check Jumper position
1
2
Magnetron has overheated but has now recovered Internal diagnostic fault
Check that magnetron cooling fan and turntable are working correctly Check installation, air inlet temperature and air
filters
1 Oven control area is overheating Check air filters.
Check axial fan Check installation for hot air intake
EPS= External Program System
Error Light Operation
The “Air Filter Blocked” light and “Service” light are triggered by the internal circuitry. If the magnetron overheats, the error code “E:7” or “E:8” is displayed on the front panel, and both the “Air Filter Blocked” and the “Service” indicators will light. Once the magnetron has cooled sufficiently to allow the oven to restart, the “Service” light will remain illuminated until the oven is turned off.
This fault may have been triggered by one of the following causes:
- Air inlet on rear of machine being obstructed.
- High air inlet temperature.
- Slow running cooling fan, jammed turntable or broken gearbox (note: cooling fan also drives turntable on EE5, CD2 and XE5 models).
- Faulty magnetron overheat ‘stat or associated wiring.
Note that the customer may not have noticed that the oven displayed “E:7” or “E:8”, and so the reported fault may be misleading.
[Service]
[Air Filter blocked]
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Page 8 400 Series Ovens 32Z3769 Issue 1
b VENTS
c TRAY HANDLE RESTS
There is one on each side of the oven for convenient storage of the tray handle.
d BAFFLE PLATE
Forms the inside rear of the oven and covers the hot air circulation fan. Removable for cleaning by unscrewing the four wing nuts which hold it in place. This must be cleaned on a regular basis, and kept free of debris.
CATALYTIC CONVERTOR
Allows extraction free cooking. Should be removed regularly for cleaning. ( Do not spray/ put caustic cleaner directly into the catalytic converter as this will cause permanent damage )
e RUNNERS
These mounted on each side of the oven cavity to support the rectangular racks or oven trays, and are for use in CONVECTION MODE ONLY.
f HOT AIR FAN
Situated behind the baffle plate, and circulates the hot air through the baffle plate, over the heating element, and around the edge of the baffle plate back into the cavity.
g OVEN CAVITY
The oven cavity is stainless steel. It must be kept clean See CLEANING.
h TURNTABLE TRAY
The vitreous enamelled turntable tray fits onto the turntable disc in the bottom of the oven cavity, and rotates during cooking to ensure an even distribution of microwave energy so that the food is cooked evenly.
j RATING PLATE
The rating plate is situated on the rear of the oven, and states the Model, Serial Number, Electrical Ratings and Manufacturers Tel no.
k DOOR
The door consists of a thermally insulated inner section, and an additional air gap provided by a twin skinned door front to lower the surface temperature.
l ON/OFF SWITCH
This is used to turn the oven On or Off. IT DOES NOT ISOLATE INTERNAL WIRING FROM THE ELECTRICAL SUPPLY.
n ELECTRICAL SUPPLY LEAD
p AIR FILTER
Main intake for cooling air for internal components. Must be clear of obstructions.
q MenuKey
Main features
b
c
d
e
f
g
h
j
k
l
m
p
n
q
rear view of Oven
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Page 9 400 Series Ovens 32Z3769 Issue 1
Electronic controls:
a Stage LED's
b Service Indicator
c Air Filter Block Indicator
e Program Display
f Temperature Set Pads
g Time / Program Number Pads
h Cancel/ Callback Pad
i Program Pad
j Convection Pad
k Microwave power Pads
l On/Off switch
m MenuKey socket
i
j
a
b
c
e
f
g
h
k
l
m
Page 10
Page 10 400 Series Ovens 32Z3769 Issue 1
Procedure B - Simplified Power Output Test for Field Service Use
You will need:
A thermometer capable of reading to ±0.1°C. A Polypropylene tray approximately 200 mm x 200 mm. A measuring jug. A calculator. Water which is at a temperature of 10°C ± 2°C.
1 Measure 1 litre of cold water into the tray using the measuring jug. 2 Measure the water temperature, and record it as T[s]. 3 Place the tray on the turntable in the oven and close the door. 4 Turn the oven on. 5 Set the timer to 1:02. ( For Manual controls use a stopwatch set to 1 minute 2 seconds ) 6 Press the “100%” power pad. 7 When the oven bleeps, open the door and remove the tray. 8 Stir the water thoroughly, and measure its temperature. Record this as T[e].
Calculation:
1 T[r] = T[e] - T[s]. 2 Power = 70 x T[r]. Power is in Watts.
The power given by the above test should be within ±10% of the rated power.
Procedure C - Power Transformer Test
You will need:
A Digital Multi-meter (D.M.M.) A Megger or similar resistance meter using 500V d.c.
1 Isolate the oven from the mains supply.
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 Po wer Transformer has High Voltages presen t
because of the Soft Start circuit. Isolate the oven before testing.
a Mains winding between tags
Approx. 1.3 Ω
b High Voltage winding
Approx. 50-100 Ω
c Filament winding
between terminals
Less than 1 Ω
Primary winding and chassis
Pass if over 10 MΩ
Filament winding and chassis
Pass if over 10 MΩ
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 continuity of the windings. Results should be as follows:
5 Using a Megger, test the insulation resistance between:
One end of the High Voltage winding is connected to the
chassis, so this is not tested.
a
c
b
Procedure A - Power Output Test In accordance with BS EN 60335-2-90 is not used in the field please
Engineers Procedure B.
Page 11
Page 11 400 Series Ovens 32Z3769 Issue 1
Procedure E - High Voltage Rectifier Test
You will need:
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.
Procedure D - High Voltage Capacitor Test
You will need: A Digital Multi-meter (D.M.M.)
A Megger or similar resistance meter using 500V d.c.
5. Using a Megger, test the insulation resistance between the terminals and the case.
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 &
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.
Between Terminals
Pass if approximately 10 MΩ
Between Terminals and Case Pass if open circuit
Between Terminals and Case
Pass if over 100 MΩ
Procedure F - Magnetron Test
You will need:
A Megger or similar resistance meter using 500V d.c.
A Magnetron can be tested for an open filament or a short circuit by carrying out a continuity check.
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 Magnetron.
4. A continuity check across the Filament terminals should be 1ohm or less
5. A continuity check between each filament terminal and the
metal outer should read open.
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
FAIL
Conducts one way only
PASS
Short Circuit both ways
FAIL
Conducts one way, leaks the other
FAIL
Page 12
Page 12 400 Series Ovens 32Z3769 Issue 1
SW2 Primary Interlock— located on the left hand side of the oven. Directly disconnects
the supply to the microwave generating circuit and thereby cuts off the microwave emissions from the oven when the door is opened.
SW1 Monitored switch—located on the same assembly as the primary. The Monitor
switch will produce a short circuit across the mains supply if the Primary interlock switch is faulty, thus blowing the microwave fuse and rendering the oven inoperative.
SW3 The Secondary interlock—located on the left hand side of the oven and like the
primary switch will cut off the microwave emission and will do so even if the primary and monitored interlock have failed open circuit.
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.
SW4 Convection fan switch—located on the same bracket as the control switch.
This switch is wired in series with the convection motor supply and will disconnect when the door is opened.
SW5 Control switch—located on the top right behind the display connects to the
logic control PCB on a black and white twisted pair of wires. It is this signal that is used by
the control circuit to determine the door position. A closed contact indicates a closed door.
Door interlock operation
The door on the oven is monitored by five microswitches. Three of these are used in the conventional “Primary, Secondary and Monitor” switch arrangement shown below, while the fourth is a low-voltage switch linked directly to the control circuitry and the fifth switches the power to the convection motor.The switches operate as follows:
Door open position
Fused
Live
Live
LHS
RHS
Control PCB
Convection Fan
Neutral
Neutral
Output
SW2 Primary
SW5
SW4
SW3 Secondary
SW1 Monitor
Page 13
Page 13 400 Series Ovens 32Z3769 Issue 1
Procedure for Door Interlock and test:
The three interlock Microswitches are located on the LHS of the oven. Release the 2 screws retaining each microswitch assembly just enough to allow the assembly to move.
The purpose of this procedure is to set the interlock so that when the door is opened more than 3mm the Oven microwave circuit is switched OFF.
The door closed position [Microwave circuit ON] is actually set with a 1mm opening to allow for heat expansion when the oven is operating at full temperature.
WARNING
Before adjusting the microswitch assemblies ensure that the oven has been isolated from the electrical supply and discharge the HT Capacitors. Please note the terminals on the microswitches remain live when the oven is
switched off, so complete isolation is essential.
1
To set Microswitches SW1 & SW2 and SW3 to OPEN [OFF] at a
door opening with a 3mm gap:
Slide forward Microswitch assembly to set SW2 to just click CLOSED
and then allow the assembly to move slightly approx. 0.05– 0.10 Inch
(1-2mm) to just allow the switch to return to the OPEN position and
tighten both screws.
Repeat for SW3 rotating clockwise to CLOSED until it just opens then anti-clockwise slightly to the OPEN position and tighten screws.
Position the door open with a 3mm gap:
Place the two 3mm Spacers over the door seal at the top of the
door on each side at the corner and carefully close the door ensuring the spacer is on the door seal.
2
3mm Spacers
Door Seal
Door
Five Microswitches: SW1, SW2 & SW3 door interlock Microswitches are located on the LHS of the oven. SW4 & SW5 are located on the RHS of oven behind the control panel. SW4 switches off the convection fan SW5 sends a ‘door open‘ signal to the Control Board
SW3
SW1 & SW2
Tools Required: Door Spacer Kit P10H0129, Multimeter
Page 14
Page 14 400 Series Ovens 32Z3769 Issue 1
3
Remove the 3mm spacers and open and close the door 2 or 3 times to allow the parts to work together.
Set a Multimeter Resistance [ ] and connect the meter to the microswitch terminals 37 &
29.
Check that microswitches SW1,SW2 and SW3 are in the CLOSED [ON] position and the Multimeter reads a minimal resistance.
If the meter reads Open Circuit, remove the 1mm spacers and repeat steps 1­4 moving the switch assemblies very slightly further down. This procedure may need to be repeated several times to achieve a satisfactory arrangement.
4
To confirm the oven operates at a 1mm door open position.
Replace the 3mm spacers with the two 1mm Spacers.
1mm Spacers
0.1
Open Circuit
3mm Spacers
The meter should now read open circuit, if not repeat steps 1 & 2 adjusting the switch assemblies slightly
upwards, ensuring the Microswitches are in the OPEN [OFF]
position.
Replace the 3mm spacers on the door and over
the corners of the seal as before.
Door Seal
Door
Door Seal
Door
Page 15
Page 15 400 Series Ovens 32Z3769 Issue 1
1 Side Panel (L/H) MC3134
2 Ferrite RMC6773
3 Upper Trim MC3120MC
4 Top Plate RMC6759EMC
6 Rear Panel MC3769MC
7 Air Filter MC3155
8 Side Panel (R/H) MC3145
Principal components: casework
9 Handle Hanger RCK6319
11 Front Lower Panel MC3047
12 Lower Trim MC3122
96 PCB Retainer 40H0084
104 Side Trim LH MC3789MC
105 Side Trim RH MC3121
140 Rubber Base seal long
Rubber Base seal short
40H0259 40H0260
1
2
4
2
6
7
8
9
12
11
96
105
104
3
140
Page 16
Page 16 400 Series Ovens 32Z3769 Issue 1
Door mechanism
13 Door Stay (R/H) MC3040
14 Hinge Body MC30121X02
15 Hook (A) RMC66171
16 Hook (B) RMC66172
17 Door Spring (B) MC3068X01
18 Hinge Body (L/H) MC30122X01
19 Door Spring (A) MC3067
20 Door Stay (L/H) MC3046
22 Solid Door Assy Silver MC3230MCX02
Page 17
Page 17 400 Series Ovens 32Z3769 Issue 1
34 Motor Bracket RMC7307X01
137 Thumb nut 31Z4031
37 Convection Motor MC3730MOD
135 Catalytic Converter 31Z1245
136A Vent Plate 40H0236
23 Turntable Disc RMC7340X01
24 Baffle Plate Bolt CP30326
25 Baffle Plate MC3018
26 Fan Fixing Cap RCK7617
27 Convection Fan MC3111
30 Oven Body MC3750MC
31 Gearbox MC3216
32 Shaft RMC7391X01
33 Motor Cooling Fan RMC7310
Oven cavity components and hot air system
136A
25
137
135
Catalytic Converter
Page 18
Page 18 400 Series Ovens 32Z3769 Issue 1
Oven door assembly
22 Solid Door Assy. MC3230MCX02
38 Door Handle Silver RBR1285048
40 Door Cover Outer 40H0080
41 Inner Panel 40H0081
42 Door Reinforcement RMC70722
43 Door Frame (B) MC3055
44 Insulation Wrap 32Z0001
46 Door Base Silver MC3031X05
47 Door Cover MC3064X01
49 Plate - Door Switch LHS MC0562MC
52 Packing (B) MC3065
53 Door Rear Plate MC3229
48 Plate - Door Switch RHS MC3056
49
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Page 19 400 Series Ovens 32Z3769 Issue 1
Door Interlock RHS, Magnetron & Stirrer Motor
129
133
61 Foam Tape 31Z0042
63 Magnetron 30Z1349
64 Magnetron Thermal trip 30Z0088
129 Turntable Motor 11H0110
54 Door Switch Bracket 40H0023
55 Microswitch SW4 30Z0240
56 Microswitch SW5 30Z0240
59 Microswitch Insulator 31Z0115
60 Outlet Duct MC3037
Page 20
Page 20 400 Series Ovens 32Z3769 Issue 1
Principal Components LHS & Rear view:
57
Microswitches
57 Secondary Microswitch SW3 30Z0240
117 Axial fan 11H0075
138 Primary Microswitch SW2 30Z1396
139 Monitor Microswitch SW1 30Z1395
37 Hot Air Motor MC3730MOD
55 Microswitch SW4 30Z0240
56 Microswitch SW5 30Z0240
69 Thermal cut-out switch 30Z1024
73 Heater Element 240V 40H0009
74 Temperature Sensor 30Z1419
143 Motor Resistor Assembly1 11H0122
142 Exhaust steam pipe MC3773
73
37
69 74
55
138
139
117
56
142
143
Note:
1. The 270Resistor is required to
drop the supply voltage to the Convection Fan Motor to 208V.
Page 21
Page 21 400 Series Ovens 32Z3769 Issue 1
Principal Components RHS 1 : Models _ EE5, _ XE5, [CD2]
128
90
76A
76
60 Outlet Duct MC3037
70 Bridge Rectifier 341520
71 No. 8 Screw 31Z3107
76 HT Capacitor 0.75uF 2500V 30Z1329
76A Capacitor Clip 30Z1261
90 Transformer 208-240 50Hz 30Z1233
117 Axial Fan 11H0075
128 Cooling Fan 240V 50Hz 11H0091
117
60
70
71
Page 22
Page 22 400 Series Ovens 32Z3769 Issue 1
Principle components RHS 2: _ EE5, _ XE5
75 HV Diode Assembly 11H0010
76 HT Capacitor 0.75uF 2500V 30Z1329
88 HT Transformer Top Bracket MC3127
89 HV Lead Assembly, Ferrite 11H0025
90 Transformer 208-240V 50Hz 30Z1233
91 HT Transformer Bottom Bracket 40H0070
92 Capacitor Band RMC7215
93 Filter Bracket 40H0065
94 HT Transformer Support Bracket MC3024
Page 23
Page 23 400 Series Ovens 32Z3769 Issue 1
Principle components RHS 3: _ XX5, _XX52
128
140
130
90
90
76A
76
76 HT Capacitor 0.75uF 2500V 30Z1329
76A Capacitor Clip 30Z1261
90 Transformer 208-240 60Hz 30Z1233
117 Axial Fan 11H0075
128 Cooling Fan 208V 50Hz 30Z1128
130 Diode Board 11H0058
140
Potentiometer1
11H0058
117
Note:
1. The
Potentiometer adjusts the cavity set point temperature
Page 24
Page 24 400 Series Ovens 32Z3769 Issue 1
77 Microwave Mains Filter 16A 30Z1340
78 Heater Mains Filter 16A 30Z1340
79 Fuse Cover 20Z1080
80 Fuse 10A HRC 30Z0217
81 Fuse Holder 1” 30Z0231
82 Fuse 13A 30Z0456
Input wiring, filters and fuses 1
Blue
78
82 79
80 79
81
111 116 113 111 115 112
112a
Green / Yellow
Brown
111 Mains Input Block 31Z0328
112 Cable Gland 31Z1070
112A Cable Gland Nut 31Z1082
115 XE5 Input Cable Assembly 302030
116 Strain Relief Grommet 31Z1036
Model 1003__XE5, XD5
Blue
Green / Yellow
Model 1003__EE5, CD2
81
77
Model:
UK
Cable
Assembly
113 _ EE, _CD2 10H0012
113 _XE5 [Single phase] 10H0011
Europe
113 _XE5 [Single phase] 10H0064
Page 25
Page 25 400 Series Ovens 32Z3769 Issue 1
Input wiring, filters and fuses 2
Model RMC1003__XX5, XX52
Green / Yellow
Blue
Brown
77 Microwave Mains Filter 16A 30Z1340
78 Heater Mains Filter 16A 30Z1340
80 Fuse 10A HRC 30Z0217
81 Fuse Holder 1” 30Z0231
82 Fuse 13A 30Z0456
78
77
80
81
82
81
L2
Green / Yellow
Blue
L1
111 Mains Input Block 31Z0328
112 Cable Gland 31Z1070
112A Cable Gland Nut 31Z1082
113 Input Cable Assembly 31Z0220
116 Strain Relief Grommet 31Z1036
111 111 115 112
112a
Model:
UK
Cable
Assembly
115 _ XX5 [Single phase] 10H0046
115 _XX52 [Twin phase] 10H0039
Europe
115 _XE5 [Single phase] 10H0065
115 _XX52 [Twin phase] 10H0063
115
Page 26
Page 26 400 Series Ovens 32Z3769 Issue 1
Control Panel 1: Electronic controls assembly
95 Membrane Assy See table
97 On/Off Switch 30Z0503
98 Logic Assy. See table
99 Support Shield 40H0075
100 M3 x 5 Screw 31Z3106
101 No. 4 x 3/8” Screw 31Z3112
102 220R 50W Resistor 30Z0235
103 Relay Assy See table
107 PCB Stand-off 31Z7010
108 15 Way Ribbon Connector 11Z0298
109
Single 0.25” Blade Tag Connector
309610
110 M3 Nylon Support 31Z0206
131 Menukey Assembly 10H0081
97
102
100
110
110
101
107
107
97
131
98
95
99
98
108
103
109
Model Membrane Assy
EE5, XE5, XX5 11H0060
XX5 Starbucks 11H0024
EE5, XE5, XX5 Menukey
11H0067
95
Model Logic PCB Relay PCB
EE5, 11H0066 11C0286
CD2, XD2 N/A 11H0027
XE5, XX5 11H0066 11H0077
98 103
Page 27
Page 27 400 Series Ovens 32Z3769 Issue 1
Control Panel 2: Membrane panel circuit
You will need:
A Digital Multi-meter (D.M.M.)
1. Isolate the oven from the mains supply.
2. Remove the Logic Assembly from the Control Panel Housing.
3. Unplug the membrane “tail” from the Logic PCB Assy.
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 housing.
525° 350° 400° 440° 480°
Page 28
Page 28 400 Series Ovens 32Z3769 Issue 1
Control Panel 3: Manual control assembly
Control Board not shown for clarity
122
121
127
123
124A
124B
124C
124D
125
126
123
97
106
105A
96
96 PCB Retainer LH 40H0084
97 On/Off Switch 30Z0503
105A Side Trim RH MC31212
106 M5 Flat Washer 31Z5004
121 PCB Assembly 11H0027
122 Timer 30Z0991
123 Amber Neon 316031
124A Control Knob Black 313020
124B Control Knob Skirt Red 313160
124B Control Knob Skirt Blue 31Z1216
124C Control Knob Cap Red 313220
124C Control Knob Cap Blue 31Z1217
124D Control Knob Shaft Adaptor 313030
124E Control Knob Assy Black/Red 11C0173
124E Control Knob Assy Blue 11C0406
125 Pushbutton (Start) 31Z0349
126 Red Neon 316030
127 Potentiometer 40C0892
96
122
Page 29
Page 29 400 Series Ovens 32Z3769 Issue 1
1 SIDE PANEL (L/H) MC3134
2 FERRITE RMC6773
3 UPPER TRIM MC3120MC
4 TOP PLATE RMC6759EMC
6 REAR PANEL MC3769MC
7 AIR FILTER MC3155
8 SIDE PANEL (R/H) MC3145
9 HANDLE HANGER RCK6319
11 FRONT LOWER PANEL MC3047
12 LOWER TRIM MC3122
13 DOOR STAY (R/H) MC3040
14 HINGE BODY MC30121X02
15 HOOK (A) RMC66171
16 HOOK (B) RMC66172
17 DOOR SPRING (B) MC3068X01
18 HINGE BODY (L/H) MC30122X01
19 DOOR SPRING (A) MC3067
20 DOOR STAY (L/H) MC3046
22 SOLID DOOR ASSY MC3230MCX02
23 TURNTABLE DISC RMC7340X01
24 BAFFLE PLATE BOLT CP30326
25 BAFFLE PLATE MC3018
26 FAN FIXING CAP RCK7617
27 FAN MC3111
30 OVEN BODY MC3750MC
31 GEARBOX MC3216
32 SHAFT RMC7391X01
33 COOLING FAN RMC7310
37 HOT AIR MOTOR MC3730MOD
38 DOOR HANDLE SILVER RBR1285048
40 DOOR OUTER 40H0082
34 MOTOR BRACKET RMC7307X01
41 INNER INSULATION PANEL 40H0081
42 DOOR REINFORCEMENT RMC70722
43 DOOR FRAME (B) MC3055
44 INSULATION WRAP 32Z0001 46 DOOR BASE SILVER MC3031X05
47 DOOR COVER MC3064X01
48 PLATE - DOOR SWITCH RHS MC3056
49 PLATE - DOOR SWITCH LHS MC0562MC
52 PACKING (B) MC3065
53 DOOR REAR PLATE MC3229
54 DOOR SWITCH BRACKET 40H0023
55 CONVECTION MOTOR
MICROSWITCH SW4
30Z0240
56 LOW VOLTAGE
MICROSWITCH SW5
30Z0240
57 SECONDARY MICROSWITCH SW3 30Z0240
59 MICROSWITCH INSULATOR 31Z0115
60 OUTLET DUCT MC3037
61 FOAM TAPE 31Z0042
63 MAGNETRON 30Z1349
64 MAGNETRON THERMAL TRIP 30Z0088
69 THERMAL CUT OUT SWITCH 30Z1031
70 BRIDGE RECTIFIER 341520
71 NO. 8 SCREW 31Z3107
72 M5 SCREW 101825
73 240V HEATING ELEMENT 40H0009
74 TEMPERATURE SENSOR 30Z1419
76 HT CAPACITOR 0.75μF 30Z1329
76A CAPACITOR CLIP 31Z1261
Part number identification chart 1
Page 30
Page 30 400 Series Ovens 32Z3769 Issue 1
Part number identification chart 2
117 80MM AXIAL FAN 11H0075
128 COOLING FAN 208V 50HZ 30Z1128
129 TURNTABLE MOTOR
11H0110
130 DIODE BOARD 11H0058
131 MENUKEY ASSEMBLY 10H0081
133 INLET DUCT MC3793
135 CATALYTIC CONVERTER 31Z1245
136A VENT PLATE 40H0221
137 THUMB NUT 31Z4031
138 PRIMARY MICROSWITCH SW2 30Z1396
139 MONITOR MICROSWITCH SW1 30Z1395
140 RUBBER BASE SEAL LONG
RUBBER BASE SEAL SHORT
40H0259 40H0260
141 POTENTIOMETER 11H0058
142 EXHAUST STEAM PIPE MC3773
143 MOTOR RESISTOR ASSY 11H0122
77 M’WAVE MAINS FILTER 16A
30Z1340
78 MAINS FILTER 16A
81 FUSE HOLDER 30Z1178
82 FUSE 20A 30Z1177
90 TRANSFORMER 208-240V 50Hz 30Z1233
95 MEMBRANE ASSEMBLY See table
96 PCB RETAINER 40H0084
97 ON/OFF SWITCH 30Z0503
98 LOGIC ASSY. See Table
99 SUPPORT SHIELD 40H0075
100 M3 X 5 SCREW 31Z3106
101 NO. 4 X 3/8” SCREW 31Z3112
102 220R 50W GOLD RESISTOR 30Z0235
103 RELAY PCB ASSY See Table
104 SIDE TRIM LH MC3789MC
105 SIDE TRIM RH MC3121
106 M4 FLAT WASHER 31Z5004
107 PCB STAND-OFF 31Z7010
108 15 WAY RIBBON CONNECTOR 11Z0298
109 SINGLE 0.25” CONNECTOR 309610
110 M3 NYLON SUPPORT 31Z0206
111 MAINS INPUT BLOCK 31Z0328
112 CABLE GLAND 31Z1070
112A
CABLE GLAND NUT 31Z1082
113 POWER CABLE ASSEMBLY 11H0115
116 STRAIN RELIEF GROMMET 31Z1036
104 PCB Retainer RH 40H0084
121 PCB Assembly 11H0027
122 Timer 30Z0991
123 Amber Neon 316031
124A Control Knob Black 313020
124B Control Knob Skirt Red 313160
124B Control Knob Skirt Blue 31Z1216
124C Control Knob Cap Red 313220
124C Control Knob Cap Blue 31Z1217
124D Control Knob Shaft Adaptor 313030
124E Control Knob Assy Black/Red 11C0173
124E Control Knob Assy Blue 11C0406
125 Pushbutton (Start) 31Z0349
126 Red Neon 316030
127 Potentiometer 40C0892
CD2 Models
Model Membrane Assy
EE5, XE5, XX5 11H0060
XX5 Starbucks 11H0024
EE5, XE5, XX5 Menukey
11H0067
95
98 103
Logic PCB Relay PCB
EE5, 11H0066 11C0286
CD2, XD2 N/A 11H0027
XE5, XX5 11H0066 11H0077
Model
Page 31
Page 31 400 Series Ovens 32Z3769 Issue 1
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:
APPENDIX 1: MenuKey™ Download Procedure
Ensure the power switch is off.
Lift the MenuKey cover in the front panel 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.
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 00:00 remove the key and close the cover. The oven is now 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. 00:00 (oven ready to use)
If the download is not successful the key number will not be displayed and if the program pads are pressed an E3 error will display.
EPS - FAIL - REDO External Program System ERROR.
If the key is removed before the download is complete or the process is interrupted the display shows “EPS” then “FAIL” then “REDO”. Switch the oven off and begin the MenuKey download again.
1
2
3
example: Key C02
example: 27 Programs
Page 32
Page 32 400 Series Ovens 32Z3769 Issue 1
Follow the SAFETY INSTRUCTIONS at the beginning of this manual.
Cleaning the control panel and exterior surfaces
Wipe down regularly with a damp cloth.
Hints and Tips for stubborn stains in the oven cavi ty
1. Switch on oven with microwave power only (without heat).
2. Place a container of water 2.5 Pints (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.
APPENDIX 2: Cleaning Procedure
2. Remove food particles from between the inside edge of the door and the front of the oven floor using a clean, dry brush ( Location A ). Apply non-caustic oven cleaner to interior surfaces except door seals and 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 to hinges.
4. Wipe door seals carefully with a clean damp cloth. Examine for signs of wear or damage.
5. Replace the Catalytic Converter and cover plate
ensuring the face of the converter with the spacing edge is facing outwards to allow air to pass efficiently through the filter.Tighten up the three thumb nuts.
6. Replace all the parts and ensure the clean air filter is in place
ALWAYS switch off at the electrical supply and allow oven to
cool for at least 20 minutes before cleaning
As required, remove carousel and wipe out spillages 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 wi se to have the electrical connections inspected periodically.
Cleaning the air filter oven cavity, and door
DO NOT SPRAY ANY CLEANING FLUID DIRECTLY INT O THE CATALYTIC CONVERTER VENT HOLES AT THE REAR OF THE OVEN CAVITY, THIS WOULD CAUSE PERMANENT DAMAGE TO THE CATALYTIC CONVERTER
1. Remove trays, racks, turntable and turntable disc from the oven cavity and air filter ( on the rear panel) . Clean using non-caustic oven cleaner. Wash off using a clean cloth and plenty of clean, warm water. Dry using a fresh, clean cloth.
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 A CLEAN AIR FILTER IN POSITION
To remove the catalytic converter at the rear of the cavity undo the
three thumb nuts to release the cover plate and carefully lift out.
Wash the catalytic converter in CLEAN HOT WATER only, do not
use cleaning products which could cause permanent damage to the filter. Leave to dry. Clean the cover plate in non-caustic oven cleaner and dry using a fresh clean cloth.
A
If the door seals are
damaged ,the oven
must be repaired by
an approved
Service Engineer
Merrychef recommends the use of approved Merrychef Oven Cleaner and Merrychef Oven Protector.
spacing
edge
Thumb Nut x3
Catalytic converter
rear of oven cavity
Page 33
Page 33 400 Series Ovens 32Z3769 Issue 1
RECOMMENDED PARTS LIST: 240V 50Hz Models _EE5, _XE5, CD2,
Page 34
Page 34 400 Series Ovens 32Z3769 Issue 1
RECOMMENDED PARTS LIST: 240V 50Hz Models _XX5, XX52
Page 35
Page 35 400 Series Ovens 32Z3769 Issue 1
Circuit Diagram: Models _ EE5
Issue 10
HEATER ELEMENT
SOFT START
RESISTOR
470 R GOLD
240
LOW
VOLTAGE
FUSE 1
10 AMP
HEATER
MEMBRANE
LOGIC BOARD
CON 2
T
MAINS
SWITCH
T1
FUSE 2
13 AMP
FILTER
FILTER
N(3) L(1)
U(4) U(2)
N(3)
U(2)
N
RL5 RL7
RL1 RL2
DOOR SWITCH
RL6
XE VERSION USE CN13
EE VERSION USE BRIDGE AND CN11
JP1 JP3JP2
SHORTING LINK
11C0286
TOP RIGHT
14 13 11 12
2
33 34 35 36
1
19 30 29 28 18 20 21 22
4
865
23
7
10 24 25
3
64
CAVITY
SENSOR
74
MAGNETRON CUT-OUT
56
LIVE
NEUT
EARTH
HOT
AIR
FAN
AXIAL
FAN
BLOWER
ASSY
TRANSFORMER
L(1)
FULL/HALF
SOFT MICRO
-WAVE
95
U(4)
ALL HEATER CIRCUIT
USES RED WIRE
AND STEEL CRIMPS
31Z0425
2787324
CAVITY oh
FAN
AXIAL
pb
pb
RHS TOP MOTOR SWITCH
SW1
LHS TOP REAR MONITOR
LHS BOTTOM BACK SECONDARY
SW3
LHS TOP FRONT PRIMARY
SW2
ACACAC
AC
142
3
1
3
2
Page 36
Page 36 400 Series Ovens 32Z3769 Issue 1
Circuit Diagram: Models _ XE5
Issue 11
HEATER
ELEMENT
470 R GOLD
FUSE 1
HEATER
MEMBRANE
LOGIC
BOARD
CON 2
T
MAINS
SWITCH
FUSE 2
FILTER
FILTER
N(3) L(1)
U(4) U(2)
N(3)
U(2)
RL5
RL1
RL2
DOOR
SWITCH
RL6
JP1 JP3
11H0077
TOP
RIGHT
14
13
33 34 35 19 30 29 28 18 20 21 22 8 6 5 23 7 10 24 25
64
CAVITY
SENSOR
74
MAGNETRON
CUT-OUT
56
LIVE
NEUT
DOOR
OPEN
POSITION
EARTH
HOT
AIR
FAN
AXIAL
FAN X2
L(1)
SOFT MICRO
-WAVE
95
U(4)
T1
SOFT
START
LIVE
2
2
MAG
FAN
COOL
240
LOW
VOLTAGE
N
TRANSFORMER
RESISTOR 270 OHMS
RHS TOP MOTOR SWITCH
36
CAVITY OVERHEAT SWITCH
1
Or
2Ph
1Ph
LHS TOP REAR MONITOR
LHS BOTTOM BACK SECONDARY
SW1
SW3
LHS TOP FRONT PRIMARY
SW2
1
3
2
Page 37
Page 37 400 Series Ovens 32Z3769 Issue 1
Circuit Diagram: Models CD2
Issue 06
11H0027 CD2 CONTROL PCB
J1 DOOR
LHS TOP PRIMARY
LHS TOP REAR MONITOR
TOP RIGHT
DOOR
MAINS SWITCH
DOOR MICROSWITCHES
TEMP SET
HEATER ON
POWER SET
COOKING
TIMER
M
12
POWER
START
80mm AXIAL FAN
CONVECTION FAN
COOLING FAN /
T/TABLE MOTOR
CAVITYSENSOR
HEATER
MAG STAT
LIVE
NEUTRAL
EARTH
LIVE
LIVE
LIVE
LIVE
LIVE
LIVE
LIVE
LIVE
Not used post feb 2009
LIVE
LIVE
LIVE
LINK FOR 30ABRIDGE FOR 13A
EARTH
NEUTRAL
NEUTRAL
NEUTRAL
NEUTRAL
NEUTRAL
NEUTRAL
NEUTRAL
NEUTRAL
NEUTRAL
RETURN
LIVE
RETURN
RETURN
VR1
VR2
J2 CAVITYTEMP
ALL HEATER CIRCUIT
USES RED WIRE
31Z0425
AND STEEL CRIMPS
31Z0511
CAVITY OVERHEAT SWITCH
L(1)
N(3)
U(2)
U(4)
RESISTOR 270 OHM
LHS BOTTOM BACK SEC
TOP RIGHT
MOTOR SWITCH
L(1)
U(2)
N(3)
U(4)
1111
RL3
FULL
RL3
FULL
ACACAC
AC
1
4
2
3
1414
2222
22
1
2
44
1717
tt
2727
S?
SW PUSHBUTTONS?SW PUSHBUTTON
2626
1 2
EARTHEARTH
HT1HT1
33
123
1515
1 2
99
2525
123
470R470R
2424
66
2222
RL1
START
RL1
START
1616
OPTO
START
OPTO
START
77
1818
2020
RL5
HEAT
RL5
HEAT
2828
1212
1 2
11
RL4RL4
3030
55
2121
RL6
HALF
RL6
HALF
2929
1919
1313
1010
123
RL2
SOFT
RL2
SOFT
88
Page 38
Page 38 400 Series Ovens 32Z3769 Issue 1
Circuit Diagram: Models _ XX5, _XX52
Issue 05
HEATER ELEMENT
470 R GOLD
FUSE 1
10 AMP
HEATER
MEMBRANE
LOGIC BOARD
CON 2
T
MAINS
SWITCH
FUSE 2
13 AMP
FILTER
FILTER
N(3) L(1)
U(4) U(2)
N(3)
U(2)
RL5
RL1
RL2
DOOR SWITCH
RL6
JP1 JP3
11H0077
TOP RIGHT
14
13
33 34 35 19 30 29 28 18 20 21 22 8 6 5 23 7 10 24 25
64
CAVITY
SENSOR
74
MAGNETRON CUT-OUT
56
LIVE
NEUT
DOOR OPEN
POSITION
EARTH
HOT
AIR
FAN
AXIAL
FAN X2
L(1)
SOFT MICRO
-WAVE
95
U(4)
T1
T2
SOFT
START
470 R GOLD
SOFT
START
9
LIVE 2
2
MAG
FAN
COOL
26
T/TABLE
MOTOR
Or
2Ph
1Ph
240
LOW
VOLTAGE
N
TRANSFORMER
RESISTOR 270 OHMS
36
CAVITY OVERHEAT SWITCH
1
LHS TOP FRONT PRIMARY
SW2
LHS TOP REAR MONITOR
LHS BOTTOM BACK SECONDARY
SW1
SW3
RHS TOP MOTOR SWITCH
33A
1
3
2
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