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Garland Mealstream, Service Manual

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Garland Mealstream Service Manual Download Page 15

Mealstream Ovens Pt. No. 32Z3403  Issue 15 

Page 15 

No 

Description 

208V 

240V 

29 

On/Off Switch  

30Z0503 

30Z0503 

30 

Control Panel Assy with Menukey 
 (except Tim Hortons) 

11C0379 

11C0379 

31 

Logic Board (except Tim Hortons) 

11C0377 

11C0377 

32 

Relay Board (except Tim Hortons) 

11C0316 

11C0212 

33 

AC Ribbon connector 

11M0116 

11M0116 

34 

DC Ribbon connector 

11M0117 

11M0117 

73 

MenuKey Assembly 

10C0148 

10C0148 

 

Electronic Control Panel Assembly  

 

32 

31 

33 

34 

29 

30 

PRINCIPAL COMPONENTS 

73 

Tim Hortons 
See page 16  

Summary of Contents for Mealstream

Page 1: ...ION MICROWAVE EMISSIONS DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY Mealstream S E R V I C E S E R V I C E M A N U A L ALL CTM3 MODELS TIM HORTON S COMBINATION OVEN MANUFACTURED FROM JANUARY 2003 ...

Page 2: ...rt 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 He...

Page 3: ...n 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...

Page 4: ...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 electr...

Page 5: ...ty 10 2 inches 260mm 19 3 inches 490mm 14 2 inches 360mm 1 62 ft 45 86 litres Weight Nett Gross packed 198 lb s 90 kg 227 lbs 103 kg Construction Cavity Casework 304 Stainless Steel Settings Microwave Temperature Timer Programs 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 Model N...

Page 6: ...dequate 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 con...

Page 7: ...ngular racks or oven trays 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 RATING PLATE The rating plate is situated on the rear of the oven and states the Model Serial Number Electrical Ratings and Manufacturers telephone number DOOR The door consists of a thermal...

Page 8: ...tion Pad f Power Pads g Time Preset Pads h Temperature Set Pads i Cancel Callback Pad j Program Pad N Menukey a b f g i j Electronic control panel h e MAIN FEATURES a b M M L K N O K Preheat L Cancel M Icon Cook Pads N MenuKey O Quarter Half Full Batch Load Tim Hortons control panel N MENU KEY ...

Page 9: ...7 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 short type 520000 520000 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 11...

Page 10: ...40 30Z0240 18 Door arm stop assembly 11C0279 11C0279 19 Door spring 520000 520000 20 Steam pipe 40C1023 40C1023 21 Steam vent guard 790061 790061 22 Temperature sensor 50E123 50E123 90 Cavity Vent Pipe 40C1013 40C1013 59 Rubber stop 31Z1150 31Z1150 95 Diode Board assy with leads 11M0325 11M0325 19 Door spring Long A 40C1141 40C1141 59 PRINCIPAL COMPONENTS 90 95 Note B See page 17 for parts Note A ...

Page 11: ...or 30Z1067 60 25mm OD Flexible conduit 314402 61 20mm OD Flexible conduit 314401 62 Capacitor clip 99mm 31Z0176 208V 30Z1171 30Z0283 30Z0861 10C0192 30Z1139 30Z1145 314402 314401 31Z0176 87 Magnetron Thermal Trip 2571016 2571016 63 Filter 30Z0997 N A 23 23 24 28 27 24 27 26 26 Top view 62 60 61 63 63 PRINCIPAL COMPONENTS 87 87 Note A This Capacitor is replaced with 0 88µf 2500V and 2 x 109mm clips...

Page 12: ... motor assembly 11C0312 11C0312 65 Capacitor 6µF 30Z1148 30Z1148 88 Overheat Safety Thermostat 30Z1024 30Z1024 94 Hot Air motor Resistor 50R N A 30Z1165 104 Twin Blower Resistor 39R N A 30Z1164 105 Twin Blower Resistor 50R N A 30Z1165 Back view PRINCIPAL COMPONENTS 64 65 88 94 104 105 ...

Page 13: ...short 790052 790052 76 Door Handle Towel Rail 32Z1064 32Z1064 77 Bolt 1 4 20 UNC 3 4 Hex 109050 109050 89 Door Handle 40C1020 40C1020 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 67 72 86 Door and cavity roof 86 71 89 77 76 108 109 107 106 93 Door Assembly Garland 11C0336 11C0336 Door Assembly T...

Page 14: ...2 100 Wire Rack 40C1011 40C1011 101 Crumb Tray RBR290X02 RBR290X02 110 Rear Outer Panel 40C0951 40C0951 100 101 98 96 99 97 No Description 208V 240V 57 Mesh washer 31Z5044 31Z5044 68 Heater element 40C0949 40C0948 69 Heater element cover plate 790047 790047 92 Tray Support 40C0950 40C0950 70 Baffle 11C0311 11C0311 103 Hot Air Impeller Securing Nut 105065 105065 102 Hot Air Impeller MC3111 MC3111 8...

Page 15: ...ept Tim Hortons 11C0379 11C0379 31 Logic Board except Tim Hortons 11C0377 11C0377 32 Relay Board except Tim Hortons 11C0316 11C0212 33 AC Ribbon connector 11M0116 11M0116 34 DC Ribbon connector 11M0117 11M0117 73 MenuKey Assembly 10C0148 10C0148 Electronic Control Panel Assembly 32 31 33 34 29 30 PRINCIPAL COMPONENTS 73 Tim Hortons See page 16 ...

Page 16: ...d 11C0402 11C0403 No Description 208V 240V 30 Control Panel Assy with Menukey 11C0413 11C0413 31 Logic Board 11C0411 11C0411 32 Relay Board 11C0402 11C0403 No Description 208V 240V 30 Control Panel Assy with Menukey 11C0414 11C0414 31 Logic Board 11C0411 11C0411 32 Relay Board 11C0402 11C0403 US English No Description 208V 240V 30 Control Panel Assy with Menukey 11C0332 11C0332 31 Logic Board 11C0...

Page 17: ...al 40C1008 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 11C0162 not shown in main views PRINCIPAL COMPONENTS 54 53 53 54 Right Hand Door Hinge Assembly Left Hand Door Hinge Assembly 55 Motor shaft screen and seal assembly Stirrer motor assembly 58 52 51 16 49 50 51 56 ...

Page 18: ...odels 6 Electrical Supply Terminal Block 31Z0149 46 Cable Gland 31Z0500 47 Gland Nut 31Z0499 91 Electrical Supply Plug 50Amp Canada 31Z0298 48 Electrical Supply Cord 3 Core 30Z1162 PRINCIPAL COMPONENTS Input wiring details Black White Green Yellow 48 46 47 6 L1 L2 Green ...

Page 19: ...300 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 19 Door spring 520000 520000 10 Door spring Long A 40C1141 40C1141 10 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 ...

Page 20: ... 11 63 Filter 30Z0997 N A 11 64 Hot air motor assembly 11C0312 11C0312 12 65 Capacitor Motor starter 30Z1148 30Z1148 12 67 Stirrer glass assy 11C0319 11C0319 13 68 Heater element 40C0949 40C0948 14 69 Element cover plate 790047 790047 14 70 Baffle 11C0311 11C0311 14 71 Door seal kit 11C0292 11C0292 13 72 Door choke 790007 790007 13 73 Menu Key Assembly 10C0148 10C0148 15 76 Handle 32Z1064 32Z1064 ...

Page 21: ... 14 100 Wire Shelf 40C1011 40C1011 14 101 Crumb Tray RBR290X02 RBR290X02 14 102 Hot Air Fan MC3111 MC3111 14 103 Hot Air Fan Securing Nut 105065 105065 14 104 Twin Blower Resistor 39R N A 30Z1164 12 105 Twin Blower Resistor 50R N A 30Z1165 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...

Page 22: ...ary 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 cm When measuring the leakage always hold the probe at 2 50mm from the test area using the probe su...

Page 23: ... 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 Fig 1 Fig 3 Fig 4 Fig 2 PROCEDURE FOR MICROWAVE LEAKAGE TEST 2 ...

Page 24: ...1 10 0 1 degree gauge 2 Place the beaker in the centre of the cavity 3 General Market Models Set Time to 1 minute 3 seconds and Power to 100 Wait until the counter reaches zero Tim Hortons Ovens With the oven in ENGINEERING MODE see Appendix 1 Press Pad 01 Cake and any Load Pad Quarter Half Full Wait until the counter reaches zero 4 Take the beaker out immediately stir the water with a plastic imp...

Page 25: ...ous 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 5 Using a Megger test the insulation resistance between Mains winding betwee...

Page 26: ...L Conducts one way leaks the other FAIL 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 ...

Page 27: ...pply 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 The door on the Mealstream oven is monitored by three micros...

Page 28: ...ogether Interlock Order SW1 Monitor 3rd SW2 Primary 1st Note both SW2 and SW3 activate together SW3 Secondary 1st Note both SW2 and SW3 activate together Step 1 Set the interlock so that they activate in the following order When closing the door When opening the door Continuity Meter Spacer No required Part No S5 Door Spacer 5mm 2 40C1118 S1 Door Spacer 1mm 2 40C1114 Door Spacer Kit Part No 10C017...

Page 29: ...seals meet Figure 1 Door top seal Door side seal Door spacer Interlock Order SW1 Monitor OPEN SW2 Primary OPEN SW3 Secondary OPEN 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 correctly and repeat steps 1 to 4 PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST 3 Please note It is very ...

Page 30: ...ip 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 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 ...

Page 31: ... 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 4 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 spacer to fill gap betwee...

Page 32: ... TDK Mounting Strip on both sides with the door in the closed position Add these two measurements together and divide by 2 Adjust hinge adjustment bolt so the door is the distance calculated from the TDK Mounting Strip and lock in position with lock nut 8 Fit door springs to door arms and to the hook at base of inner side panels Check operation of door and remove LHS spring 7 Fit RHS and LHS door ...

Page 33: ...fingers Left S215 4 Choke fingers Right S215 11 Tape choke Spacer S325 to the cavity base and tape choke Spacers S215 to sides and top of door choke Close the door and centralise the door choke Fit the remaining 20 M5 washers and nuts tighten the fixings evenly 10 Loosely fit 3 off M5 flat washers 3 off M5 shockproof washers and 3 off M5 stainless steel full nuts Remove spacing pieces and check do...

Page 34: ...piece into the remainder of the door foil facing out 13 Place the outer skin over the door frame assembly and fix with 7 of M3x12 counter sunk screws around the LHS RHS and top of the door PROCEDURE FOR BUILDING AND FITTING MEALSTREAM DOOR Please note It is very important after completing this procedure to carry out a Door interlock adjustment and test procedure See pages 27 29 ...

Page 35: ...e 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 Perfor...

Page 36: ...Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 PROCEDURE FOR REPLACING DOOR SEAL ASSEMBLY 2 Please note It is very important after completing this procedure to do a Door interlock adjustment and test procedure See pages 27 29 ...

Page 37: ...PLATE M6 x 12mm stainless steel Hex Head screw Pt No 80T7133 M5 stainless steel dome nut Pt No 80X7025 Shelf runner Element cover plate 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 cov...

Page 38: ... 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 ...

Page 39: ...otor Earth tag then undo all securing nuts from the motor mounting plate and remove the fan motor assembly 7 Check the position and condition of the hot air motor damper seal this a important microwave leakage seal in the motor shaft screen See page 17 8 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 s...

Page 40: ...er 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 i...

Page 41: ... Temperature Stat Screw Figure 1 Figure 3 4 x Magnetron screw fixings Figure 4 Screws Temperature Stat Figure 5 Figure 6 Wire mesh Magnetron mount Temperature Stat PROCEDURE FOR REPLACING MAGNETRON ASSEMBLY 2 Please note After completing this procedure do a microwave leakage test See page 22 23 ...

Page 42: ...e 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 PROCEDURE FOR TESTING MEMBRANE PANEL CIRCUIT Mealstream 501 US ...

Page 43: ...Page 43 Mealstream 501 US Tim Hortons Unbranded Variant PROCEDURE FOR TESTING MEMBRANE PANEL CIRCUIT 2 Mealstream 501 US Tim Hortons French Canada Note PINS 1 4 Lower Layer Pins 5 10 upper layer Note PINS 1 4 Lower Layer Pins 5 10 upper layer ...

Page 44: ...Mealstream Ovens Pt No 32Z3403 Issue 15 Page 44 CIRCUIT DIAGRAM ALL MODELS BEFORE 05 28 02 30Z1177 30Z1177 30Z1177 30Z1177 ...

Page 45: ...Mealstream Ovens Pt No 32Z3403 Issue 15 Page 45 CIRCUIT DIAGRAM ALL MODELS AFTER 05 28 02 11 10 02 ...

Page 46: ...177 SW1 SW2 SW3 30Z0240 30Z0240 30Z0240 39R 50W FILTER 1 FILTER 2 FILTER 3 FILTER 4 OMIT FILTER 3 4 FOR 240V VERSION 1A 30Z0957 6uF TEST 1 TEST 2 TEST 3 TEST 4 TEST POINTS 1 2 3 4 INTERLOCK BLUE BROWN RED YELLOW NO COLOR GOLD RESISTOR GOLD RESISTOR MAGNETRON OVERHEAT L 2 N 4 3 U 1 U 3 U 1 U L 2 N 4 L 2 N 4 3 U 1 U 3 U 1 U N 4 L 2 BLUE BROWN SEE NOTE 1 39R 50R NOTE 1 ON 240V 60HZ VERSION ONLY 208V ...

Page 47: ...Mealstream Ovens Pt No 32Z3403 Issue 15 Page 47 CIRCUIT DIAGRAM ALL MODELS AFTER 04 06 03 ...

Page 48: ... been set TIM HORTONS No cook program assigned to selected pad Set a time Set a valid time Use call back to check program Ensure correct Menukey is installed switch oven off then on to show key No 1 2 Oven not heating up Possible Heater fault Check heater fuse Confirm operation of heater circuit 1 Oven Cavity overheating Confirm heater relay is operating Check sensor 1 Oven is not at correct tempe...

Page 49: ...rams In order to carry out the Power Test and Microwave Leakage Test on Tim Hortons variant Ovens the Icon Pad programs on the control panel need to be switched to Engineering Program Mode Engineering Mode does not affect the current Menukey program settings for the Icon pads and the current Menukey programs are automatically restored when the oven is next switched on To switch to Engineering Mode...

Page 50: ...splaying 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 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 o...

Page 51: ...Min Rate kΩ Standard Rate kΩ Max 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 R 200 C 1 kΩ 5 Temperature Sensor Resistance Note These resistances will only be apparent in a stable cavity temperature as the sensor has a slow response time ...

Page 52: ...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 Garland Description of error Suggestion for improvement to manual Please return this form to Garland Commercial Industries 1177 Kamato road Mississauga Ontario L4W 1X4 CANADA Attn Servic...

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