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Merrychef HD, Service Manual

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Merrychef HD Service Manual Download Page 16

Page 16 

Microcook HD Ovens 32Z3385 Issue  5  

Control panel assembly ( 

For KFC models see Appendix 1 )

 

38 

39 

40 

41 

42 

43 

44 

No  Description 

All Models 

40  Electrostatic Screen 

40M0464 

41  Ribbon Connector (10 Way) 

11M0117 

42  Filtered Wire Assembly 

11M0333 

43  M4 Nylon Face Nut 

31Z4014 

44  M3 x 12 Hex Head 

31Z3117 

No.  Description 

Colour 

HD1425 
HD1925 

HD2025 

TA1725 

TA1925 

9  Door screen 

Red/Grey 

40M0923 

40M0858 

40M0923 

40M0923 

9  Door screen 

Blue 

40M1053 

40M1054 

40M1053 

40M1053 

38  Switch Panel Assy 

Red/Grey 

11M0108 

11M0110 

11M0299 

11M0395 

38  Switch Panel Assy 

Blue 

11M0387 

11M0388 

11M0386 

11M0395 

39  Logic Board 

——— 

11M0107 

11M0107 

11M0359 

11M0359 

49  PCB relay 

——— 

11M0427 

11M0427 

11M0430 

11M0430 

50  Fan Control PCB 

——— 

——— 

——— 

11M0261 

11M0261 

HD1025 

40M0923 

40M1053 

11M0108 

11M0387 

11M0107 

11M0285 

——— 

See Appendix 6 for Logic Board connections and jumper details  

Summary of Contents for HD

Page 1: ...NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY Microcook HD Microcook TA S E R V I C E M A N U A L S E R V I C E M A N U A L For all Microcook HD TA models manufactured from January 2001 Part No 32Z3385 Issue No 5 Merrychef ...

Page 2: ...nent Layout HD2025 20 Component Layout TA 1725 TA 1925 21 Cavity Components 22 Door Mechanism Right side 23 Door Mechanism Left side 24 Hot Air Motor Assembly 25 Microcook TA Fan Control PCB and Heater Setup 26 27 Input Wiring Details 28 Part Number Identification List 29 30 Wiring Diagrams 31 35 Appendix 1 KFC components 36 Appendix 2 Capacitors and Magnetrons 37 Appendix 3 Cleaning 38 Appendix 4...

Page 3: ... to removing the rear cover from the oven 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 mains isolator switch Upon completion of a service on an Microcook oven or before reconnecting the appliance to the mains supply for testing check all of the following points All internal electrical connections are co...

Page 4: ...t Weight Nett Gross packed 42 5kg 45kg Construction Cavity Casework 304 Stainless Steel 304 Stainless Steel Coated Aluminium extrusions Settings Microwave Timer 100 50 Defrost Up to 10 minutes Up to 3 cooking stages of up to 10 minutes each Program Model Number Model prefix Type Voltage Frequency UK Export Customer For example 1925C450UK Model 1925 Microcook 230 240V 50Hz UK model Product specific...

Page 5: ...499mm Plus 50 mm clearance behind Internal Dimensions Height Width Depth Capacity 200mm 390mm 365mm 28 5 Litres 1 01ft Weight Nett Gross packed 42 5kg 45kg Construction Cavity Casework 304 Stainless Steel 304 Stainless Steel Coated Aluminium extrusions Settings Microwave Timer TA1725 100 50 turbo TA1925 100 heat only turbo Up to 9 minutes 59 seconds Up to 3 Programmed cooking stages of up to 9 min...

Page 6: ...ted at 16A 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 50mm clearance all around the oven Air intake temperature should not exceed 35 C excessive temperature can lead to reduced operating duty cycle or premature ageing of internal components NEVER Install an oven above fryers grills g...

Page 7: ...lace membrane panel Replace membrane panel Check correct time is set ie 1 00 minute Not 60 seconds Error codes and diagnostics The Microcook 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 Display Fault frequency Recommended Action 1 2 Microcook TA Convected hot air failure p...

Page 8: ... not to break it during use Method A cylindrical container of borosilicate glass is used for the test It has a maximum thickness of 3mm an external diameter of approximately 190mm and a height of approximately 90mm The mass of the container is determined At the start of the test the oven and the empty container are at ambient temperature Potable water having an initial temperature of 10 C 1 C is u...

Page 9: ...nce 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...

Page 10: ...rk 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 T...

Page 11: ...shown below Door Interlock Arrangement Monitor Secondary Power In Power Out L N Primary The switches operate as follows 1 Monitor Switch TopRight As the door is closed the monitor switch is opened 2 Primary Interlock Switch Bottom Left The Primary switch is then closed 3 Secondary Interlock Switch Bottom Right The Secondary Switch then closes When the door is opened the switches operate in the rev...

Page 12: ... Features a Program Pad b On Off Switch c Program Display d Program Selection Time Set Pads e Power Selection Pads HD models 100 50 de frost TA models 100 hot air turbo f Time Display g Cancel Callback Pad h Door h b C microcook a c d f g e turboaire ll C e Vend model KFC ...

Page 13: ...4 31Z1104 31Z1104 4a Screw M5x16 31Z3022 31Z3022 31Z3022 31Z3022 31Z3022 31Z3022 4b M5 Star Washer 31Z5012 31Z5012 31Z5012 31Z5012 31Z5012 31Z5012 5 Installation Label 31Z2071 31Z2071 31Z2071 31Z2071 31Z2071 31Z2071 6 Self Adhesive Foam Tape 31Z0158 31Z0158 31Z0158 31Z0158 31Z0158 7 Service History Label 31Z2056 31Z2056 31Z2056 31Z2056 31Z2056 31Z2056 Rear cover assembly HD1025 only Rear View All ...

Page 14: ...ng Nut M5 31Z4013 31Z4013 31Z4013 31Z4013 31Z4013 31Z4013 14 Fixing Bolt M5 x 16 31Z3022 31Z3022 31Z3022 31Z3022 31Z3022 15 Door Main Body 40M0839 40M0839 40M0839 40M0839 40M0855 40M0839 16 Door Mesh 40M0841 40M0841 40M0841 40M0841 40M0860 40M0841 17 Door Choke 40M0840 40M0840 40M0840 40M0840 40M0840 18 Choke Filler Horizontal 40M0931 40M0931 40M0931 40M0931 40M0862 40M0931 19 Choke Filler Vertica...

Page 15: ...75 20Z1075 20Z1075 20Z1075 40M0859 20Z1075 21 Silicone Sealant White 31Z0098 31Z0098 31Z0098 31Z0098 31Z0098 31Z0098 22 Door Seal Horizontal 40M0927 40M0927 40M0927 40M0927 40M0861 40M0927 23 Door Seal Vertical 40M0926 40M0926 40M0926 40M0926 20Z0499 40M0926 24 Loctite Gel 32Z5005 32Z5005 32Z5005 32Z5005 32Z5005 32Z5005 25 Door Mesh Spring Vertical 20Z0338 26 Door Mesh Spring Horizontal 40M0863 27...

Page 16: ...on Colour HD1425 HD1925 HD2025 TA1725 TA1925 9 Door screen Red Grey 40M0923 40M0858 40M0923 40M0923 9 Door screen Blue 40M1053 40M1054 40M1053 40M1053 38 Switch Panel Assy Red Grey 11M0108 11M0110 11M0299 11M0395 38 Switch Panel Assy Blue 11M0387 11M0388 11M0386 11M0395 39 Logic Board 11M0107 11M0107 11M0359 11M0359 49 PCB relay 11M0427 11M0427 11M0430 11M0430 50 Fan Control PCB 11M0261 11M0261 HD...

Page 17: ...30Z0270 30Z0270 30Z0270 30Z0270 62 Thermal Trip Magnetron 25Z1016 30Z0257 30Z0257 30Z0257 30Z0257 30Z0257 63 Magnetron 64 Cold Air Duct 40M0884 40M0544 40M0544 40M0544 40M0544 40M0544 65 Diode Assembly 11M0343 11M0343 11M0343 11M0343 11M0343 11M0343 66 Delta Filter 31Z0126 31Z0126 31Z0126 31Z0126 31Z0126 31Z0126 67 Air Outlet Duct 40M0509 40M0509 40M0509 40M0509 40M0509 40M0509 68a Fuse Holder 30Z...

Page 18: ...r 40M0973 40M0973 40M0973 40M0973 61 Magnetron Cooling Fan 30Z0921 30Z0270 30Z0270 30Z0270 30Z0270 30Z0270 62 Thermal Trip Magnetron 25Z1016 30Z0257 30Z0257 30Z0257 30Z0257 30Z0257 63 Magnetron 64 Cold Air Duct 40M0884 40M0544 40M0544 40M0544 40M0544 40M0544 65 Diode Assembly 11M0343 11M0343 11M0343 11M0343 11M0343 11M0343 66 Delta Filter 31Z0126 31Z0126 31Z0126 31Z0126 31Z0126 31Z0126 67 Air Outl...

Page 19: ...Cover 40M0973 40M0973 40M0973 40M0973 61 Magnetron Cooling Fan 30Z0921 30Z0270 30Z0270 30Z0270 30Z0270 30Z0270 62 Thermal Trip Magnetron 25Z1016 30Z0257 30Z0257 30Z0257 30Z0257 30Z0257 63 Magnetron 64 Cold Air Duct 40M0884 40M0544 40M0544 40M0544 40M0544 40M0544 65 Diode Assembly 11M0343 11M0343 11M0343 11M0343 11M0343 11M0343 66 Delta Filter 31Z0126 31Z0126 31Z0126 31Z0126 31Z0126 31Z0126 67 Air ...

Page 20: ...er 40M0973 40M0973 40M0973 40M0973 61 Magnetron Cooling Fan 30Z0921 30Z0270 30Z0270 30Z0270 30Z0270 30Z0270 62 Thermal Trip Magnetron 25Z1016 30Z0257 30Z0257 30Z0257 30Z0257 30Z0257 63 Magnetron 64 Cold Air Duct 40M0884 40M0544 40M0544 40M0544 40M0544 40M0544 65 Diode Assembly 11M0343 11M0343 11M0343 11M0343 11M0343 11M0343 66 Delta Filter 31Z0126 31Z0126 31Z0126 31Z0126 31Z0126 31Z0126 67 Air Out...

Page 21: ...mex Cover 40M0973 40M0973 40M0973 40M0973 61 Magnetron Cooling Fan 30Z0921 30Z0270 30Z0270 30Z0270 30Z0270 30Z0270 62 Thermal Trip Magnetron 25Z1016 30Z0257 30Z0257 30Z0257 30Z0257 30Z0257 63 Magnetron 64 Cold Air Duct 40M0884 40M0544 40M0544 40M0544 40M0544 40M0544 65 Diode Assembly 11M0343 11M0343 11M0343 11M0343 11M0343 11M0343 66 Delta Filter 31Z0126 31Z0126 31Z0126 31Z0126 31Z0126 31Z0126 67 ...

Page 22: ...355 20Z1355 20Z1355 40M0853 20Z1355 78 White Silastic 31Z0098 31Z0098 31Z0098 31Z0098 31Z0098 31Z0098 79 Roof 40M0563 40M0563 40M0563 40M0563 40M0563 40M0877 80 Stirrer Blade Assembly 11M0140 11M0140 11M0140 11M0140 11M0140 11M0140 81 Box Launch Seal 40M0832 40M0832 40M0832 40M0832 40M0832 40M0832 82 Tuning Stub 40M0508 40M0508 40M0508 40M0508 40M0539 40M0508 ...

Page 23: ...noid Plunger 20Z0970 20Z0970 20Z0970 20Z0970 20Z0970 93 Moulded Rubber Stop 31Z1002 31Z1002 31Z1002 31Z1002 31Z1002 94 Moulded Rubber Stop Fixing Screw 31Z3012 31Z3012 31Z3012 31Z3012 31Z3012 95 Microswitch Straight Arm 30Z0240 30Z0240 30Z0240 30Z0240 30Z0240 30Z0240 96 Microswitch Monitor 30Z0356 30Z0356 30Z0356 30Z0356 30Z0356 30Z0356 97 Microswitch Insulation Pad 31Z0115 31Z0115 31Z0115 31Z0115...

Page 24: ... Solenoid Plunger 20Z0970 20Z0970 20Z0970 20Z0970 20Z0970 93 Moulded Rubber Stop 31Z1002 31Z1002 31Z1002 31Z1002 31Z1002 94 Moulded Rubber Stop Fixing Screw 31Z3012 31Z3012 31Z3012 31Z3012 31Z3012 95 Microswitch Straight Arm 30Z0240 30Z0241 30Z0242 30Z0243 30Z0244 30Z0245 96 Microswitch Monitor 30Z0356 30Z0356 30Z0356 30Z0356 30Z0356 30Z0356 97 Microswitch Insulation Pad 31Z0115 31Z0115 31Z0115 31...

Page 25: ...0Z1355 20Z1355 20Z1355 20Z1355 40M0853 20Z1355 78 White Silastic 31Z0098 31Z0098 31Z0098 31Z0098 31Z0098 31Z0098 79 Roof 40M0563 40M0563 40M0563 40M0563 40M0563 40M0877 80 Stirrer Blade Assembly 11M0140 11M0140 11M0140 11M0140 11M0140 11M0140 82 Tuning Stub 40M0508 40M0508 40M0508 40M0508 40M0539 40M0508 83 Hot Air Motor Assembly 11M0344 84 Cooling Sleeve 40M0878 84 83 ...

Page 26: ...ut When power is connected to the oven the Sensor Error LED D6 should not illuminate If this happens there is a bad connection or a broken wire in the thermocouple sensor Using a suitably insulated pair of long nose pliers short the terminals together D6 should then go out If this does not happen the PCB is faulty and requires replacing Thermocouple Operation Using a multimeter set to read in exce...

Page 27: ...ure 5 With the meter still attached press pad 0 When the oven time display indicates 2 48 note the voltage reading This should be between 2 0V and 7 5V Press the Cancel Pad 6 Measure the voltage between the Set Temp pin and GND pin and adjust VR1 until the meter reads the same as the reading obtained above 7 Press Pad 0 again and verify that the Half Full LED D7 switches on and off during the cook...

Page 28: ...30Z0168 30Z0168 30Z0168 30Z0168 68c Fuse Cover 20Z1080 20Z1080 20Z1080 20Z1080 20Z1080 20Z1080 73 Mains Filter 30Z0997 30Z0997 30Z0997 30Z0997 30Z0997 30Z0997 101 Sleeve 89W6010 89W6010 89W6010 89W6010 89W6010 89W6010 102 Clip 31Z7052 31Z7052 31Z7052 31Z7052 31Z7052 31Z7052 U U N L2 Green Yellow Blue Brown Blue 102 102 68A 101 73 Model HD1025 Model HD2025 Input wiring details 68B 68C ...

Page 29: ...20Z0499 40M0926 24 Loctite Gel 32Z5005 32Z5005 32Z5005 32Z5005 32Z5005 32Z5005 25 Door Mesh Spring Vertical 20Z0338 26 Door Mesh Spring Horizontal 40M0863 27 Door Packer 20Z0488 28 Tessa Tape 31Z0042 31Z0042 31Z0042 31Z0042 31Z0042 31Z0042 29 Top Door Trim 40M0856 30 Door Handle 40M0857 31 Handle End Cap L H 40M0523 32 Handle End Cap R H 40M0524 33 M6 Full Nut 31Z4009 35 M5 Flat Washer 31Z5008 36 ...

Page 30: ...8 31Z0098 31Z0098 31Z0098 79 Roof 40M0563 40M0563 40M0563 40M0563 40M0563 40M0877 80 Stirrer Blade Assembly 11M0140 11M0140 11M0140 11M0140 11M0140 11M0140 81 Box Launch Seal 40M0832 40M0832 40M0832 40M0832 40M0832 40M0832 82 Tuning Stub 40M0508 40M0508 40M0508 40M0508 40M0539 40M0508 83 Hot Air Motor Assembly 11M0344 84 Cooling Sleeve 40M0878 85 Door Guide Moulding L H 20Z0310 20Z0310 20Z0310 20Z...

Page 31: ...Page 31 Microcook HD Ovens 32Z3385 Issue 5 Circuit diagram Microcook HD 1025 HD1425 HD1725 HD1925 HD2025 ...

Page 32: ...Page 32 Microcook HD Ovens 32Z3385 Issue 5 Circuit diagram Turboaire II XE Single leaded Part 1 ...

Page 33: ...Page 33 Microcook HD Ovens 32Z3385 Issue 5 Circuit Diagram Turboaire II XE Single leaded Part 2 ...

Page 34: ...Page 34 Microcook HD Ovens 32Z3385 Issue 5 Circuit Diagram Turboaire II XE Twin leaded Part 1 ...

Page 35: ...Page 35 Microcook HD Ovens 32Z3385 Issue 5 Circuit Diagram Turboaire II XE Twin leaded Part 2 ...

Page 36: ...nel Assy 11M0394 39 Logic Board 11M0416 49 Relay Board 2 Buzzers 11M0285 103 Menukey Assembly 10C0148 104 Top Panel Extrusion 40M1062 105 MenuKey connection lead 11H0064 106 Diode PCB 11M0364 49 APPENDIX 1 KFC models 103 104 As Microcook HD1925 except the following parts Top View See Appendix 6 for Logic Board connections and jumper details ...

Page 37: ...5 0 88µF 30Z1330 0 75µF 30Z1329 HD 1725 HD 1925 2x 1 1µF 30Z1242 HD 2025 2x 1 1µF 30Z1242 TA 1725 2x 1 0µF 30Z1331 TA 1925 2x 1 1µF 30Z1242 2x 1 0µF 30Z1331 SANYO MAGNETRON Oven Model Capacitor LH Capacitor RH HD 1025 1 25µF 30Z1078 1 only HD 1425 0 88µF 30Z1330 1 0µF 30Z1331 HD 1725 HD 1925 2x 1 25µF 30Z1078 HD 2025 2x 1 25µF 30Z1078 TA 1725 2x 1 1µF 30Z1242 TA 1925 2x 1 25µF 30Z1078 2x 1 1µF 30Z...

Page 38: ...er of water 1 5 litres into the centre of the oven cavity 2 Set timer to 9 minutes 3 Set microwave power to 100 4 At end of steam cycle wipe out cavity with a clean cloth Hints and Tips for stubborn stains in the oven cavity Wipe down regularly with a damp cloth Cleaning the control panel and exterior surfaces DO NOT USE THE OVEN WITHOUT A CLEAN AIR FILTER IN POSITION 1 Ease the air filter cover f...

Page 39: ...y 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 b...

Page 40: ... which are unique to our requirements To overcome this we need to use the FLM020 fuses Pt No 30Z1177 for the Microwave circuit on all Microcook HD1725 HD1925 ovens The operation listed below is to be followed to any service calls where the 13A A S fuses have blown 1 Isolate oven from mains power supply 2 Remove rear cover to obtain access to the side of the oven 3 Strip back the GSS sleeving over ...

Page 41: ...d F 9 Connect the BROWN mains wire to the bottom location on the new fuse holder Pt No 30Z1178 connect the filter wire L2 to the top location of the fuse holder G 10 Fit the fuse holder into position using Pt No 31Z3061 x1 in the upper most hole location ensure screw is bias towards the right hand side of the slot H 11 Re fit the blue cover to the 10AMP fuse holder And fit the 20AMP fuse Pt No 30Z...

Page 42: ... This is clearly indicated on the PCB itself 2 As Jumper 1 3 01 NC N A 02 2025 Jumper ON 2025 03 1925 Jumper ON 1925 04 1725 Jumper ON 1725 05 1425 Jumper ON 1425 06 1025 Jumper ON 1025 07 30 prog Jumper always ON 08 Multi Jumper always ON 09 Cook Jumper always OFF 10 Man Jumper OFF Automatic door Jumper ON Manual door APPENDIX 6 Logic Board Magnetron Failure Detect 11M0416 KFC optic Logic PCB wit...

Page 43: ...w of any forms returned will be made on a regular basis and the manual will be updated if required Name Address Page on which error occurs if applicable Microcook HD TA Description of error Suggestion for improvement to manual Please return this form to Manual corrections and modifications Service Dept Merrychef Limited Station Road West Ash Vale Aldershot Hampshire GU12 5XA United Kingdom Tel 44 ...

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