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Merrychef Mealstream, Service Manual

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Mealstream Ovens 32Z3387 Issue 2  

 

CAUTION MICROWAVE EMISSIONS 

 

DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE 

GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY 

S

E

R

V

I

CE

 M

ANUAL

 

M e a l s t r e a m  

S E R V I C E   M A N U A L  

For all Mealstream models manufactured from January 2001  

Part No. 32Z3387e  Issue No. 2 

Summary of Contents for Mealstream

Page 1: ...ISSIONS DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY S E R V I C E M A N U A L M e a lstre a m S E R V I C E M A N U A L For all Mealstream models manufactured from January 2001 Part No 32Z3387e Issue No 2 ...

Page 2: ... components LHS 13 Principal components RHS 14 Principal components Top 15 Principal components not shown in main views 16 Interlock Operation 17 Electronic Control Panel Assembly 18 Manual Controls Panel Assembly 19 Membrane Panel Circuit 20 Complete Spare Part Listing 21 22 Electrical Diagram 23 Electrical Diagram 24 Manual corrections and modifications 25 Merrychef Limited Station Road West Ash...

Page 3: ...he 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 mains supply for testing check all of the following points All internal ele...

Page 4: ...m clearance behind Internal Dimensions Height Width Depth Capacity 260 mm 490 mm 360 mm 45 86 litres 1 62 ft Weight Nett Gross packed 90 kg 106 kg Construction Cavity Casework 304 Stainless Steel Settings Microwave Temperature Timer 100 75 50 25 Convection only Off 150 175 200 225 250 C Up to 30 minutes Up to 3 cooking stages of up to 30 minutes each Programmed Series 5 Model Number Voltage Freque...

Page 5: ... gap of at least 3 mm should be fitted 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 50 mm clearance at the sides and rear of the oven and at least 50 mm above Air intake temperature should not exceed 35 C excessive temperature will lead to reduced operating duty cycle or premature agei...

Page 6: ...t temperature and air filters 1 2 3 No time has been set Invalid time has been set Invalid program has been set Set a time Set a valid time Use call back to check program 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 temperature to start program Re...

Page 7: ...y 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 RATING PLATE The rating plate is situated on the rear of the oven and states the Model Serial Number Electrical Ratings and ...

Page 8: ...e LED s b Program Time Display c Service Indicator d Air Filter Block Indicator e Convection Pad f Power Pads g Time Precept Pads h Temperature Set Pads i Cancel Callback Pad j Program Pad a b c f g i j Electronic controls Mealstream Series 5 d h e ...

Page 9: ...eam Ovens 32Z3387 Issue 2 a Power Neon Amber b Control Knob c Start Push button d Cook cycle Neon Red e Heater Neon Amber a e Manual controls Mealstream CD2 d c merryFKHI Mealstream CD 2 START TIME POWER TEMP C b b b ...

Page 10: ...e care not to break it during use Method A cylindrical container of borosilicate glass is used for the test It has a maximum thickness of 3 mm an external diameter of approximately 190 mm and a height of approximately 90 mm 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...

Page 11: ...00V d c 1 Isolate the oven from the mains supply 2 Ensure that the High Voltage Capacitor is discharged before commencing work 3 Remove all connections from the Power Transformer 4 Using a D M M check the resistance of the windings Results should be as follows WARNING High voltages and large currents are present at the secondary winding and filament winding of the Power Transformer It is very dang...

Page 12: ... 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 E High Voltage Rectifier Test You will need A Megger or similar resistance meter using 500V d c 1 Isolate the oven from the mains supply 2 Ensure that the High ...

Page 13: ...holder 30Z0231 30Z0231 4A Fuse 13 amp 30Z0168 30Z0168 5 Fuse holder 30Z0231 30Z0231 5A Fuse 13 amp 30Z0168 30Z0168 6 Mains terminal block 31Z0149 31Z0149 7 Filter Heater circuit 30Z0997 30Z0997 8 Filter Microwave circuit 30Z0997 30Z0997 9 Door spring 520000 520000 10 Door arm stop assembly 11C0279 11C0279 11 Microswitch Primary 30Z0240 30Z0240 12 Door hinge assembly LH 11C0167 11C0167 13 Door arm ...

Page 14: ...ssembly 11C0300 11C0300 16 Door hinge assembly RH 11C0166 11C0166 17 Microswitch Secondary 30Z0240 30Z0240 18 Door arm stop assembly 11C0279 11C0279 19 Door spring 520000 520000 20 Steam pipe 790046 790046 21 Steam vent guard 790061 790061 22 Temperature sensor 50E123 50E123 See page 16 for parts Principle components ...

Page 15: ...1Z0121 25 HT diode 30Z0246 31Z0246 26 Capacitor 1 1 µf 30Z0861 30Z0861 27 Transformer 30Z0992 30Z0992 28 Twin blower motor 310110 310110 60 25mm OD Flexible conduit 314402 314402 61 20mm OD Flexible conduit 314401 314401 62 Capacitor clip 31Z0175 31Z0175 23 23 24 25 28 27 24 25 27 26 26 Top view Principle components 62 60 61 ...

Page 16: ...eater element Principle components No Description 208 240 67 Stirrer glass 40C0954 40C0954 68 Heater element 40C0949 40C0948 69 Element cover plate 790047 790047 70 Baffle 2 No 11C0311 11C0311 71 Door seal kit 11C0261 11C0261 72 Door choke 790007 790007 ...

Page 17: ...6 50 Left Hand Assembly 11C0167 51 Pin 790027 52 Roller 40C0752 53 Bolt 101825 54 Nut 80X7003 55 LH Hinge bracket 790024 56 RH Hinge bracket not shown 790025 No Description All models 58 Stirrer motor assembly 11C0162 No Description All models 57 Hot air motor 11C0161 Principle components not shown in main views 54 51 52 55 ...

Page 18: ...387 Issue 2 INPUT WIRING DETAILS Blue Brown Green Yellow 48 46 47 No Description SERIES 5 CD 6 Mains Terminal Block 31Z0149 31Z0149 46 Cable Gland 31Z1070 31Z1070 47 Gland Nut 31Z1082 31Z1082 48 Mains Cable 3 Core 31Z0148 31Z0148 6 ...

Page 19: ...wave fuse and rendering the oven inoperative The Secondary interlock switch will cut off the microwave emission if the other switches 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 Door Interlock Operation Door Interlock Arrangem...

Page 20: ... Control Panel Assembly Mealstream Series 5 30 32 31 33 34 29 No Description Series 5 29 On Off Switch 30Z0503 30 Control Panel Assembly 11C0294 31 Logic Board 11C0213 32 Relay Board 11C0212 33 AC Ribbon connector 11M0116 34 DC Ribbon connector 11M0117 ...

Page 21: ...9 41 38 44 38 No Description Series 5 35 PCB Assembly 11C0295 36 ac voltage connector 6 way 11M0116 37 dc voltage connector 10 way 11M0117 38 Red Neon 316030 39 Timer 30Z0991 40 Potentiometer 5k 40C0892 41 Amber Neon 316031 29 On off switch 30Z0503 43 Panel assembly 11C0307 44 Pushbutton 31Z0349 45 Timer knob 11C0173 ...

Page 22: ... 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 1 10 ...

Page 23: ... arm stop assembly 11C0279 13 11C0279 13 11 Microswitch Primary 30Z0240 13 30Z0240 13 12 Door hinge assembly LH 11C0167 13 11C0167 13 13 Door arm assembly 11C0300 13 11C0300 13 14 Microswitch Monitor 30Z0240 13 30Z0240 13 15 Door arm assembly 11C0300 14 11C0300 14 16 Door hinge assembly RH 11C0166 14 11C0166 14 17 Microswitch Secondary 30Z0240 14 30Z0240 14 18 Door arm stop assembly 11C0279 14 11C...

Page 24: ...31 20 43 Panel assembly 11C0307 20 44 Pushbutton 31Z0349 20 45 Timer knob 11C0173 20 46 Cable Gland 31Z1070 17 31Z1070 17 47 Gland Nut 31Z1082 17 31Z1082 17 48 Mains Cable 3 Core 31Z0148 17 31Z0148 17 49 Right Hand Assembly 11C0166 18 11C0166 18 50 Left Hand Assembly 11C0167 18 11C0167 18 51 Pin 790027 18 790027 18 52 Roller 40C0752 18 40C0752 18 53 Bolt 101825 18 101825 18 54 Nut 80X7003 18 80X70...

Page 25: ...Page 25 Mealstream Ovens 32Z3387 Issue 2 CIRCUIT DIAGRAM Series 5 Part 1 ...

Page 26: ...Page 26 Mealstream Ovens 32Z3387 Issue 2 CIRCUIT DIAGRAM Series 5 Part 2 ...

Page 27: ...Page 27 Mealstream Ovens 32Z3387 Issue 2 CIRCUIT DIAGRAM CD2 Part 1 ...

Page 28: ...Page 28 Mealstream Ovens 32Z3387 Issue 2 CIRCUIT DIAGRAM CD2 Part 2 ...

Page 29: ...Page 29 Mealstream Ovens 32Z3387 Issue 2 US circuit diagram ...

Page 30: ...e 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 on which error occurs if applicable Mealstream Description of error Suggestion for improvement to manual Please return this form to Quality Department Merrychef Ltd Station Road West Ash Vale Aldershot Hampshire GU12 5XA Or Fax it on 44 0 1252 3...

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