110
Merrychef conneX
®
service and repair manual
7 Circuit boards and diagrams
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7 CIRCUIT BOARD S AND DIAGRAMS
Door switches – LV safety interlock circuit
Overheat thermostats – ELV safety circuit
1000W Ovens
2000W Ovens
Page 1: ...Service repair manual Microwave combination oven Part number 32Z9170 Read instructions before use Models 50Hz 60Hz Language ENGLISH ...
Page 2: ...icing and repair 14 2 11 Hazards and safety precautions when taking the appliance out of service 17 2 12 Safe working during electrical installation 18 2 13 Electrical installation requirements 19 2 14 Safe working when testing components 20 2 15 Process for discharging the capacitors 21 2 16 Safe working when replacing appliance parts 22 3 Technical data 24 3 1 Technical data charts 24 3 2 Dimens...
Page 3: ...ace assembly 83 6 10 Replacing the IO Board Input Output Board 86 6 11 PM Personality Module replacement 87 6 12 Replacing the stirrer motor and stirrer assembly 88 6 13 Replacing the convection fan motor 90 6 14 Replacing a transformer high voltage 91 6 15 Removing the convection fan motor speed controller 93 6 16 Replacing the heating element 94 6 17 Overview further components 95 6 18 Technical...
Page 4: ... products We have an environmental management policy that not only ensures compliance with all environmental regulations and laws but also commits us to continuous improvement of our green credentials We have developed a quality and environmental management system in order to guarantee the continued manufacture of high quality products and to be sure of meeting our environmental targets Environmen...
Page 5: ...n 220 230V 50Hz 208 240V 60Hz 200V 20 220V Frequency 5 50Hz Lead 6 A Z 60Hz Examples A L N E 1 5mm B L1 L2 L3 N E 2 5mm G L1 L2 L3 N E 4mm H L N E 4mm Plug A Z Examples A UK 13A 3 pin C 32A 3ph D 16A 3ph 90o E 32A 1ph Communication L USB LAN WiFi Version Accessory Customer Region Country A B 1 2 BK TL WW EU US A B pre production 1 2 serial production Carbon Black exterior Stainless Steel exterior ...
Page 6: ... work with the microwave combination oven must have read and understood the following parts of this document before starting any work Section 2 For your safety The sections that describe the activity to be carried out Safety alert symbol Symbol Meaning Warns of potential injuries Heed all the warning notices that appear after this symbol to avoid potential injuries or death Form of warning notices...
Page 7: ...n with your body 6 Only use electrically rated screwdrivers for adjusting pots etc ensuring the tool touches nothing else 7 Ensure the test equipment is set correctly before use 8 Test equipment such as meter test leads or clamps must be fitted and removed whilst the unit is dead for each and every test 9 Do not undertake functional magnetron testing with the panels of the casing removed 10 Avoid ...
Page 8: ...d repair work is the area around the appliance If it is not possible to obtain full access to all sides of the appliance move it to a better location following all manual handling recommendations 2 3 Personal protective equipment Moving and setting up the appliance Activity Materials used Personal protective equipment Conveying within the establishment Setting up the appliance on a work surface st...
Page 9: ... by hand Handling spray bottles Cleaning chemicals approved by the manufacturer Protective chemicals approved by the manufacturer Items of protection equipment depending on cleaning chemical being used Breathing mask Safety goggles Protective gloves Protective clothing apron The EC safety datasheet for the relevant cleaning chemical contains a more precise specification of these items An up to dat...
Page 10: ...ported set up installed and placed into operation as indicated in section 6 of the conneX Installation and User manual and the person responsible for placing it into operation has confirmed this The microwave combination oven must only be operated when all safety devices and protective equipment are fitted in working order and fixed properly in place The manufacturer s regulations for operation an...
Page 11: ...tion 6 Protective Earth Ground 7 Equipotential bonding Area Warning sign Description 1 Microwaves warning There is a risk of external and internal burns of body parts following exposure to microwave energy 2 Electric shock warning There is a risk of electric shock if the appliance is serviced without disconnecting the electrical supply 3 Fire electric shock warning There is a risk of fire electric...
Page 12: ... door Protects the user and outside environment from hot steam and microwave energy Check the door regularly for damage and replace it if required 5 no picture Door interlocks Ensures that the microwave generation system cannot be powered when the door is open Check door switches Open the appliance door fully during pre heat or when the oven is at temperature The Door Open message is displayed 6 n...
Page 13: ... hot appliance parts food containers and other accessories used for cooking Hot steam vapour liquids 2 When cooking food the microwave combination oven may generate hot steam and vapour which escapes when the appliance door is opened and which is removed through the air vents on the rear of the microwave combination oven when the appliance door is closed This poses a risk of scalding from hot stea...
Page 14: ...to injuries especially in the area of the torso Use a forklift truck or pallet truck to place the appliance in the installation position or to move it to a new position When shifting the appliance into the correct position use enough people for the weight of the appliance when lifting it value depending on age and gender Observe the local occupational safety regulations Wear personal protective eq...
Page 15: ...ered with insulating material so as to prevent danger that danger may arise unless a It is unreasonable in all the circumstances for it to be dead and b It is reasonable in all the circumstances for the service technician to be at work on or near it while it is live and c Suitable precautions including where necessary the provision of suitable protective equipment are taken to prevent injury When ...
Page 16: ...s While appliances are being moved on a wheeled platform Disconnect the appliance from the electrical supply before moving it Safety hazard smoke or fire Danger Where or in what situations does the hazard arise Preventative action Risk of fire smoke from defective electrical components or wrong electrical connections If one of the electrical components is defect for example due to a short circuit ...
Page 17: ...ssing your body When moving the appliance onto and off the moving equipment Use a forklift truck or pallet truck Do not exceed safety limits for lifting and carrying Wear personal protective equipment Safety hazard mechanical parts of the appliance Danger Where or in what situations does the hazard arise Preventative action Risk of body parts being crushed if the appliance tips over or falls off W...
Page 18: ...ns require protection by a residual current device RCD Suitable residual current devices meeting the relevant national regulations must be used If the installation includes more than one appliance one residual current device must be provided for each appliance Disconnection device An easily accessible all pole disconnection device with a minimum contact separation of 3 mm must be installed close t...
Page 19: ... appliance Low impedance electrical supply This commercial combination microwave oven complies with EN 61000 3 11 However when connecting sensitive equipment to the same supply as the appliance the user should determine in consultation with the supply authority if necessary that a low impedance supply is used Electrical supply Illustration Phase Meaning Single phase UK 13A models are fitted with a...
Page 20: ...inside the cavity and on the inside of the appliance door You may get burnt if you touch any of the interior parts of the cooking chamber the inside of the appliance door or any parts that were inside the oven during cooking Before starting servicing and repair work wait until the cooking chamber has cooled to below 50 C 122 F or use the Cool down function to cool the cooking chamber Wear personal...
Page 21: ...ulated gloves Voltage tester checker Process for carrying out modification change Cool down the oven then isolate from the mains supply by disconnecting the plug and fitting a suitable locking off device orlocking in the off position the isolation switch if the oven is hard wired Ensure your proprietary voltage tester is working correctlyand prove the mains supply is dead Wait 5 Minutes to allow t...
Page 22: ...n oven are removed there is a risk of electric shock from touching live parts Make sure that any work on the electrical system is performed solely by a qualified electrician from an authorized service company Before removing the covers Switch the appliance off and disconnect the plug from the wall socket Turn off the isolator switch to disconnect fixed wired appliances and lock off Take protective...
Page 23: ...chamber has cooled to below 50 C 122 F or use the Cool down function to cool the cooking chamber Wear personal protective equipment Microwave emissions WARNING Risk of burns from microwave emissions Do not become exposed to emissions from the microwave generator or parts conducting microwave energy Never operate an appliance that has failed the Microwave leakage test Fire smoke in the appliance WA...
Page 24: ...ncluding packaging 68 7 kg 151 lbs conneX16 high power version including packaging 79 2 kg 175 lbs conneX12 high power version excluding packaging 58 7 kg 130 lbs conneX16 high power version excluding packaging 67 2 kg 148 lbs conneX12 standard power version including packaging 60 0 kg 133 lbs conneX12 standard power version excluding packaging 50 0 kg 111 lbs Safety clearances Right Left 0 mm 0 i...
Page 25: ...mode convected heat microwave W 900 1000 1300 1000 900 1000 1300 1000 Electrical connected load ratings X16 High power version Electrical supply 1N 220 230V 50Hz 2N 380 400V 50Hz 1N 220V 60Hz 2 200V 50 60Hz Connections used L N E L1 L2 N E L N E 2P E Arrangement Single phase Twin phase Single phase Two pole Max power input W 6000 2500 3300 6000 6000 Rated current per phase A 32 16 32 32 32 Power o...
Page 26: ...or is open Live runs through these switches Sequence When opening the door SW3 opens first then SW2 opens lastly SW1 closes When closing the door SW1 opens first then SW2 closes lastly SW3 closes SW1 SW2 250VAC 22A SW3 250VAC 20A up to 75A inrush Check operation in Diagnostic View Check F5 F6 Check for continuity Check for proper wiring Check for proper adjustments Check for physical damage such a...
Page 27: ...rer Motor s Mounts directly on the wave guide above the cavity supply voltage connected directly from the IO Board Driving the stirrer antennae in the horn area of the microwave launch on the cavity through the gear assembly Drives a stirrer antenna to evenly distribute or scatter microwaves into the oven cavity 230VAC 2 7W Resistance 7 8kΩ Check for opens shorts or grounds Check for locked rotor ...
Page 28: ... Check convection fan motor IP connections on VFD Follow Convection Motor Trouble shooting checks Overheat Thermostat Over Temp Stat Cavity Stat Manual reset capillary tube normally closed monitors cavity temperature Opens when the cavity temperature gets too hot Breaks control safety circuit control voltage signalling the IO Board to de energise heating and microwave circuits based on the tempera...
Page 29: ...netron 6 5A 7 5A at 230VAC See HV Components in Section 5 8 for further rating information NOT TO BE TESTED LIVE Follow all test procedures in Section 5 8 Check for opens shorts grounds Check IO Board connections X400 X401 X403 X410 X411 X412 Check IO LEDs LD4 LD5 LD21 Check Error Log for E101 E113 events HV Transformer s One HV Transformer fitted as standard two HV Transformers fitted to High Pow...
Page 30: ...X412 Check IO LED 3 4 Check Error Log for E101 E113 events Thermocouple Provides DCmV to the IO Board Relay Board that represents the cavity temperature Two dis similar metals connected at the tip that produce different repeatable millivolts while exposed to different temperatures Green is negative and White is positive See chart below for reference E111 error when open circuit fault exists Check ...
Page 31: ...ack to contents Merrychef conneX service and repair manual 31 3 2 Dimensional drawings conneX 12 Front view door closed Cavity dimensions door closed View from the top door closed View from the right hand side door open ...
Page 32: ...hnical data Back to contents Merrychef conneX service and repair manual 32 conneX 16 Front view door closed Cavity dimensions door closed View from the top door closed View from the right hand side door open ...
Page 33: ... of all cooking profiles available Press Go Press Go allows quick access to use the cooking profiles that are already stored Preheat Preheat is used to control the appliance operating temperature upto six preheats can be stored on the appliance Settings Settings is used to control the appliance settings and functions including time and language loading cooking profiles and for service and maintena...
Page 34: ...ard Keyboard scroll Select the numbers key to switch numbers special characters keyboard Press the letters key to return to the letters keyboard Keyboard scroll Select the up arrow to scroll the keyboard screen for lowercase Enter OK Select the green check mark to confirm settings and continue Previous screen Select the backspace key to return to a previous screen Character length For names of coo...
Page 35: ... onto the sides of the inside of the oven the back the base and the oven door Avoid the roof and door seal 7 leave to soak for 5 10 minutes for the cleaner to work and clean the cook plate 8 Clean the cavity with a non abrasive sponge Wipe off the cleaner with a wet cloth ensuring all cleaning chemicals and debris are removed The cavity roof and door seal can also be gently wiped if necessary to r...
Page 36: ...er code for the programs you want to load into the memory and the correct file structure 1 With the appliance switched OFF 2 Open the filter cover access the USB port and lift the cover up 3 Plug in the USB memory stick 4 Switch the appliance ON 5 After the Welbilt start up screens the oven will display the menu or choices of menus that can be selected of the USB 6 Select menu file and then the gr...
Page 37: ...ferred from the USB stick It is recommended to save the existing oven menu files before uploading new firmware If you have a menu file on your USB memory stick then the menu of the appliance will be overwritten If you do not have a menu file on your USB memory stick the menu of the appliance stays as it is USB file structure Main firmware only Itemised firmware Main firmware menu files There are t...
Page 38: ... The firmware starts downloading Download progress from the USB memory stick is displayed Updating DO NOT SWITCH THE OVEN OFF UNTIL COMPLETE 4 Once loaded the oven will reboot 5 The main firmware file contains firmware for both boards If a newer IO Firmware version is available a prompt will appear Select the tick The IO firmware starts downloading Download progress from the USB memory stick is di...
Page 39: ...See section 6 11 for replacing components Manual updates 1 With the oven switched off open the cover of the USB port and insert the USB memory stick into the slot The USB memory stick should be formatted to FAT32 with the required firmware loaded 2 Switch on the oven and wait until the Merrychef screen is displayed Select the settings icon 2a The settings can also be accessed from the main screen ...
Page 40: ... and then the green tick The IO firmware will then start updating After an update of the appliance firmware check to ensure the latest firmware has been successfully loaded on to the oven Once the oven is switched back on it will cycle through the Welbilt brand names until reaching the Merrychef Expanding Your Opportunities screen Select the information i button Review the data displayed Select th...
Page 41: ...lay for error messages If an error is shown refer to the Fault Finding within section 5 3 of this manual 6 If a firmware update is required follow the instructions under Firmware updates within section 4 5 of this manual before continuing with the service procedure Enter service mode 1 Switch on the oven and wait until the Merrychef screen is displayed Select the settings icon 2 Enter the authoris...
Page 42: ...ocedures Temperature Calibration To enter the oven cavity temperature calibration mode when the appliances operating temperature requires re calibrating Demo Mode Directly selectable using the slide on off button to place the oven in demonstration mode In demonstration mode the appliance operates normally but does not engage the microwave or heater circuits Warranty Check the warranty status of th...
Page 43: ...n and select Updates 2 Open the cover of the USB port and insert the USB memory stick into the slot 3 Select Download to USB on the Updates Downloads screen 4 A pop up screen confirms completion of thedownload Select the grey tick and remove theUSB from the appliance 5 Return to the main menu using the back key on the bottom left hand corner of the screen ...
Page 44: ... selected 3 Selecting Details shows more information pertaining to the entry Event code Time and date of the entry Event description Supply voltage Supply frequency UI IO board ambient tempratures Cavity temprature Convection fan speed Cooling fan speed Magnetron s current draw The diagnostics view screen can be accessed by selected the button in the bottom right of the screen 4 Selecting Diagnose...
Page 45: ...e and repair manual 45 Further details can be read by copying the event log to a USB and opening the files on a computer Display colour codes Grey Normal operation standby Green On OK Blue Off OK Selected Yellow Warning out of normal range Red Warning switched off ...
Page 46: ... magnetron operating hours high power ovens Right hand magnetron operating hours Number of door openings Number of times the filter is removed Heating element s operating hours Total oven time in hours Number of completed cleaning cycles Ambient temperature around the control circuitry Number of individual recipe cook cycles Percentage of ambient chilled frozen food products cooked Time breakdown ...
Page 47: ...correctly Replace the air filter and the colour should change back to grey 4 Open the oven door Check the colour of the door symbol changes from grey to green on the display to check that the door microswitch interlock circuitis operating Place door spacers onto the oven door refer to Adjusting the door microswitches interlocks in the Replacing components within section 6 5 for details to confirm ...
Page 48: ... high voltage circuit live See Replacing components within section 6 of this manual Dual magnetron models Test the magnetrons individually and together Selecting the magnetrons again at any point will turn them off Using heat proof gloves remove the container and close the oven door Note The operating magnetron s will be displayed green 8 Select the heater The heating element runs for 5 minutes Se...
Page 49: ... running microwave Stirrer Motor s Cooling Fan Convection Fan From here the oven information can be viewed and the oven settings can also be accessed by pressing the appropriate button If the oven information or settings buttons are not selected after 5 seconds the oven then preheats or displays a preheat temperature choice when more than one is configured on the oven Once preheated the oven displ...
Page 50: ... A current draw lower than 5A indicates a fault in the secondary circuit wiring and components after and including the HV transformer Isolate the power supply and test the high voltage components HV transformer s diode s capacitor s magnetron s and connections to find the fault for repair DO NOT SUSPECT IT S THE MAGNETRON AT FAULT FIRST Go to the event logs is the mains voltage normal at time of f...
Page 51: ... Ambient 70 C 2Mins air filter removed and replaced E103 ambient overheat Please contact your Merrychef service partner to resolve Restart button displayed E104 cavity overheat stats released UI displays E104 Cavity Overheat stat triggered Please contact your Merrychef service partner to resolve The safety thermostat circuit 12vdc is open circuit IO connections X512 Manually reset the cavity overh...
Page 52: ...nsfer the uSD from the old UI to the new UI Loading of new up to date firmware is a must E109 IO PM Error UI displays E109 IO PM error Please contact your Merrychef service partner to resolve The PM code is incorrect for the IO board Check the PM chip is correctly in place on the IO board Replace PM chip The UI has a dedicated part number on the PM chip which is unique for UI board Ensure the corr...
Page 53: ...d failure Replace IO board Don t forget to remove the old PM chip and insert into the new IO board Download the up to date firmware from merrycheftechnical com and load on to the oven if required E113 MAGNETRON ON WITHOUT REQUEST UI displays E113 Microwave On Without Request Please contact your Merrychef service partner to resolve A current draw 1A detected on the IO board when the microwave circu...
Page 54: ...verheat and cause the magnetron overheat thermostat s to open circuit The panels are designed to guide the cooling air sufficiently through the cooling fins in a forced airflow manner UI displays Message 1 if Mag stat 125 C open circuit Pre air filter removal E117 Magnetron overheat detected Please remove replace and clean the air filter located below the door Message 2 if Mag stat 125 C open circ...
Page 55: ... On Event log only Touch screen on switch used Solution not required if events correspond with normal operation E100 Main Power On Event log only IO board supplied with 12V once mains power is switched on Solution not required if events correspond with normal operation Error Codes generated during recommission test E89 Recommission Cooling Test Failed User input X to confirm not working or timed o...
Page 56: ...brated Microwave safe 600 ml glass beaker Microwave safe 2 litre container 5 5 mm socket wrenchTorque wrench Door Spacer Kit 4mm 2mm 1000 volt rated general hand tools 1000 volt proof insulted rubber glovesPPE 5 6 Testing selected components casing mounted Technical advisory notice PAT testing of Merrychef ovens While testing with a Portable Appliance Tester PAT is not an automatic requirement for...
Page 57: ...adfrom the appliance to a portable appliance tester 2 Connect the earth from theportable appliance tester to the equipotential bonding point on the oven 3 Place the portable appliance tester in an open area such as the floor awayfrom any persons Perform a Class 1 test in accordance with tester instructions A PASS indicates the oven earthing circuit is functioning correctly If a FAIL is indicated i...
Page 58: ...s 5 Place the container centrally into the cavity 6 Select Microwave Power from the service settings tests microwave power 100 for 60 seconds convection fan at 10 1 When the countdown has finished remove the container from the cavity Immediately stir with a plastic implement and measure the water temperature 2 Calculate the temperature rise of the water end temperature minus the start temperature ...
Page 59: ...ensuring the probe sensor is reading 50 mm from the test area The leakage should not exceed 5 mW cm 1 Add 275 ml of cold water into a 600 ml microwave safe container 2 Place the 600 ml container in the centre of the cavity and close the door 3 Enter Service Settings Tests and select Microwave leakage from the appliance tests microwave power 100 for 30 seconds convection fan at 10 4 Set the leakage...
Page 60: ...a calibrated temperature probe in the centre of the cavity 2 When selected the oven heats up to 275o C 3 The preheat status can be viewed by selecting temperature 4 Once the oven reaches temperature select the green tick to start The oven will run on heat only convection fan at 100 for 30 minutes cycling around the maximum cavity temperature of 275o C 5 Independently monitor the cavity temperature...
Page 61: ...t the test 6 On completion of the test specify the result by selecting Pass or Fail 7 Safely remove the container of water from the cavity Note Opening the door during the test will stop the test Reselect the test to run again This test only generally recommended for workshop activities Recommissioning test checking the appliance operation The recommission tests are performed following the complet...
Page 62: ...l stop at any point a failure is detected After a test has successfully passed when requested select the green check mark to continue Selecting the red check mark as a result of a failure will terminate the recommission test sequence Note If the door is opened during the microwave circuit test the process will stop and record a failure 3 When all the tests have been successfully performed the disp...
Page 63: ...rect order 7 The door operation is smooth 8 The door seal is in good condition and seals against the cavity 9 The casing is securely refitted with no trapped wires and all the fixing bolts are refitted Service Settings Temperature Calibration Check Recalibration Tools required 1 x Calibrated digital thermometer 1 x Temperature probe on a heat sink 1 Place temperature probe in the centre of cavity ...
Page 64: ...w within the recommended guidelines If the temperature reading is unstable and not calibrating correctly 1 Disconnect and isolate the appliance from the electricity supply and Lock off see section 2 14 Safe working when testing components 2 Take protective measures to ensure the power cannot be switched on again 3 Allow the appliance to cool down 4 Remove the side and top panels of the casing 5 Di...
Page 65: ...any electrical measurements on the high voltage circuits including the magnetron filament whilst the oven is connected to the mains power supply 1 Remove all connections from the transformer 2 Using a Digital Multi Meter DMM check the resistance of the windings Results should be as follows 200 230V Transformer 3 Mains winding between tags approx 0 to 230 0 6 Ω 0 to 200 0 5 Ω 200 to 230 0 1 Ω 208 2...
Page 66: ... met before starting the test The appliance has been disconnected from the power supply and protective measures have been taken to ensure the power cannot be switched on again The appliance is cool The high voltage capacitors are discharged before commencing work See section 2 15 How to discharge the conneX HV The casing of the appliance has been removed DANGER High voltages and significant curren...
Page 67: ... insulation tester display reads an infinite resistance open circuit Repeat the test for the other filament terminal and the metal outer case 5 8 Mains voltage components casing removed Convection fan motor The convection fan motor is a 3 phase AC motor having a maximum speed of approximately 7000 rpm approximately 5200 rpm 16A 13A ovens controlled by a motor speed controller VFD The windings are ...
Page 68: ...without express instruction from Merrychef Convection fan motor and motor speed controller tests Ensure the following requirements have been met before starting the test The appliance has been disconnected from the power supply and protective measures have been taken to ensure the power cannot be switched on again The appliance is cool The high voltage capacitors are discharged before commencing w...
Page 69: ... work it is essential that you familiarize yourself with the rules and hazard warnings specified in section 2 For your safety specifically section 2 16 Safe working when replacing appliance parts Tools required HV Capacitor discharge tool Digital Multi Meter D M M Proprietary voltage detector Electrical lock out tools equipment Door spacer kit 2 x 4mm 2mm Spacers M2 hex key socket M5 5 hex socket ...
Page 70: ...ontents Merrychef conneX service and repair manual 70 1 23 19 22 17 21 24 2 3 20 4 15 8 9 30 10 11 12 5 29 28 6 6 2 Overview View left hand side View right hand side 19 26 17 1 22 23 21 20 27 18 24 2 3 15 9 14 13 6 4 10 11 12 25 33 5 ...
Page 71: ...6 Replacing components Back to contents Merrychef conneX service and repair manual 71 View rear side ...
Page 72: ...low within the oven cavity 16 Exhaust pipe The exhaust pipe leads excessive steam from the cavity to the cooling duct and the rear air outlet of the oven 17 Cooling duct The cooling duct directs heat generated by the magnetron s to the rear of the oven 18 SMPS low voltage IO The low voltage ELV Switch Mode Power Supply module feeds the IO board 19 Magnetron s high voltage A magnetron generates mic...
Page 73: ...ching the top panel to the back panel X12 two bolts X16 three bolts Lift the top panel at the rear and pull out from the front fixing to remove it 2 Removing the side panels Unfasten the six M5 5 hex head flange bolts three per side at the back panel of the appliance attaching each side panel to the back panel Slide the panels towards the back of the appliance and out at the bottom to remove them ...
Page 74: ...panel to ensure the cavity overheat thermostat re set button lines up correctly with the access hole in the panel INCORRECT CORRECT 6 4 Removing fitting the door assembly and hinges Component Tools required Two locking pins M5 5 hex socket wrench M8 hex socket wrench Torque wrench PZ1 Pozidriv screwdriver Requirements Check that the following requirements have been met The appliance has been disco...
Page 75: ... refitting the door choke ensure the studs are positioned correctly in the centre of the hole and not resting on the shoulder of the stud The nuts should be retightened diagonally in the following sequence to 2 1 Nm 8 Wear gloves when removing or refitting insulation pads mats in the door Refitting the door assembly Follow the steps in the reverse order to refit the door to the oven Holding the do...
Page 76: ...ly bolts should be torqued up to 3 5Nm The switch assembly adjuster and fixing bolts should be torqued up to 2 1Nm Refit the door as previously described Set the door switch adjustment and ensure the operation is correct 6 5 Adjusting the door microswitches interlocks Component Requirements Check that the following requirements have been met The appliance has been disconnected from the power suppl...
Page 77: ...rowave circuit F6 F7 fuse to blow the secondary SW2 and monitor SW1 microswitches must be replaced due to exposure to high short circuit currents The purpose of the following adjustment procedure is to set the interlock to switch off the microwave circuit when the door is opened more than 5 mm and for the microwave circuit to operate when the door is closed and the door seal expands 1 Open the app...
Page 78: ...e switch actuator 13 As soon as the secondary door switch SW2 closes nip up the two flange head screws to 2 1Nm 14 Tighten the interlock adjuster locking nut against the bracket using a 7mm spanner to 1Nm 15 Remove the spacers then open and close the appliance door a few times to validate the door switches operate in the correct sequence 16 Once the panels have been refitted conduct a microwave le...
Page 79: ...ner and lift off the door seal 5 Place the new door seal over the door in the same place as the old one and insert the metal clips in each corner 3 Remove remaining residue sealant using the knife or similar to make the surface is as flat and clean as possible 6 Press down firmly to tightly secure the door seal onto the door Ensure it is level and square Wipe off any excess sealant protruding for ...
Page 80: ...ket wrench Torque wrench Discharge Tool Requirements Check that the following requirements have been met The appliance has been disconnected from the power supply and protective measures have been taken to ensure the power cannot be switched on again The appliance is cool The top rear left and right panels of the casing of the appliance have been removed The high voltage capacitors are discharged ...
Page 81: ...s one pair of bolts on each side of the magnetron s 9 Lift the magnetron out of the waveguide 10 Remove the magnetron overheat thermostat s and earth tab for refitment on to the replacement magnetron s Fitting a magnetron Follow the steps in the reverse order to fit a replacement magnetron Ensure the magnetron overheat thermostat is refitted in the same location to ensure correct operation Ensure ...
Page 82: ...discharged before commencing work Discharge cooling capacitor with discharge tool across the Molex connector X12 remove the SW3 bracket from the left hand door hinge assembly as detailed in section 6 4 and swing out of the way The wiring does not require disconnection X16 remove the convection motor speed controller VFD assembly and swing out of the way The wiring does not require disconnection 1 ...
Page 83: ...been disconnected from the power supply and protective measures have been taken to ensure the power cannot beswitched on again The appliance is cool Anti static precautions have been taken The top left and right panels of the casing of the appliance have beenremoved The high voltage capacitors are discharged before commencing work 1 Unfasten the single M5 5 hex head flange bolt fixing the front pa...
Page 84: ... and refit the clamp using the location pin as a guide Do not overtighten the eight posidrive screws clamping the UI to the glass panel 0 7 Nm Ensure the cables are not trapped when refitting the panel to the oven and reclip the loom to the underside of the IO board Replacing the UI assembly for new 1 Ensure that the uSD card is removed from the old UI and fitted to the new assembly Check that the...
Page 85: ...rough the appliance setup to set confirm a language b date time c Connectivity WIFI Ethernet KitchenConnect 4 Check the IO and UI versions are the latest release If not execute a firmware update using the latest versions Seesection 4 5 for details 5 Recommission the under in the Service Settings ...
Page 86: ...ired M7 hex socket wrench spanner Discharge Tool The appliance has been disconnected from the power supply and protective measures have been taken to ensure the power cannot be switched on again The appliance is cool The side and top panels of the appliance have been removed The high voltage capacitors are discharged before commencing work Anti static precautions have been taken Removing the IO Bo...
Page 87: ... Check that the following requirements have been met The appliance has been disconnected from the power supply and protective measures have been taken to ensure the power cannot be switched on again The appliance is cool The side and top panels of the casing of the appliance have been removed The high voltage capacitors are discharged before commencing work Anti static precautions have been taken ...
Page 88: ...g of the appliance have been removed The high voltage capacitors are discharged before commencing work M5 5 hex socket wrench Pozidriv PZ1 screwdriver M7 hex socket wrench Torque wrench Discharge Tool Removing the stirrer motor 1 Unplug the stirrer motor from the IO Board connection X112 2 Unfasten the two M3 x 8 Poszi screws holding the motor to the waveguide and lift out Removing the microwave s...
Page 89: ... looking up Hold the stirrer cog located next to the motor cog to prevent the stirrer motor from rotating 8 Remove any remains of the old gasket from the top of the cavity before fitting a new partition plate comes with gasket to ensure a good seal Fitting the stirrer motor and assembly Follow the steps in the reverse order to fit the stirrer motor and stirrer IMPORTANT Follow the steps in the rev...
Page 90: ...of the cavity 2 Disconnect the convection fan wiring from the motor speed controller VFD drive 3 Disconnect the two heater wires see section 6 16 4 Locate the M7 hex nut and remove the steam vent pipe 5 Remove the cable ties fixing the wiring to either side of the fan motor and move the wiring clear of the back of the oven 6 Locate the ten nuts fixing the plate carrying the convection fan motor to...
Page 91: ...lockwise 6 14 Replacing a transformer high voltage Component The X16 has two HV transformers side by side at the rear of the oven under the cavity The right hand transformer is for the right hand microwave circuit components The left hand transformer is for the left hand microwave circuit components The X12 standard power variants have a single HV transformer at the rear of the oven under the cavi...
Page 92: ...in access for removal of the front HV transformer Fitting a transformer high voltage Follow the steps in the reverse order to fit the high voltage transformer s The fixing nuts should be torqued down to 3 5Nm On the X12 high power variants the HV transformer connections on the front HV transformer are on the left hand side The connections of the rear HV transformer are on the right hand side looki...
Page 93: ...s removed The high voltage capacitors are discharged before commencing work Anti static precautions have been taken Tools required M7 hex socket wrench Torque wrench Removing fitting the convection fan motor speed controller 1 Unfasten the two M7 hex head flange nuts 2 Unplug all the electric cables 3 Refit in reverse order reconnecting the cables to the convection fan motor speed controller and f...
Page 94: ... is removed The high voltage capacitors are discharged before commencing work See section 6 13 for convection fan motor assembly removal to access the heating element Additional Tools required 7mm open spanner The element is fixed using two M7 hex bolts on the X12 three on the X16 tightened to 2 1 Nm and supported with a single M5 5 hex flange nut on the X12 two on the X16 tightened to 1 7 Nm Use ...
Page 95: ...place by M10 flange nuts and graphite stud gasket torqued to 0 6Nm The nuts are locked with a screw Removable diffuser in the cavity The rear air diffuser plate in the cavity prevents large foodstuff from hitting the rear of the cavity Loosen the bottom two M7 hex nuts and unfasten the top two M7 hex nuts to remove refit Protective earth connections to casing M8 nut Equipotential bonding connectio...
Page 96: ...r 2ph ovens L1 N connected to bottom filter live on the top terminal neutral on the bottom terminal L2 connected to the top filter top terminal and neutral linked from bottom filter US ovens supply connected to the bottom filter L1 on the top terminal L2 on the bottom terminal both linked up to the top filter Diode s high voltage Fitted by two pozidriv PZ2 screws to 1Nm One high voltage diode 1000...
Page 97: ...ostat probe is located on the left hand side of the cavity The probe has a self locating pressing within the bulb slotting into the locating bracket held on to the cavity with a single M3 flange nut torqued to 1 2Nm Ensure when fitting that the probe is equal length on both sides within the fixing bracket The cavity overheat thermostat switch is located at the rear of the oven mounted on the left ...
Page 98: ...ot require adjustment The green LED is illuminated to show correct functionality Capacitor s high voltage The high voltage capacitor is located on top of the cavity and is fixed by a sheet metal bracket and a pozidriv PZ2 screw The high power 2000W conneX variants comprises two high voltage capacitors again located on the top of the cavity on each side each attributed to a magnetron Centre RH Magn...
Page 99: ...erters Once the fan motor assembly has been removed from the rear of the cavity the four M7 hex nuts should be removed at the rear of the cavity inside to allow removal of the internal box and catalytic converters The upper catalyst is fitted using two M7 hex flange nuts tightened to 2 1 Nm The lower catalyst is again fitted using two M7 hex flange nuts tightened to 2 1 Nm Air Filter Microswitch T...
Page 100: ...hex nuts and connected directly to the UI loom on the underside of the IO Board Note a second useable USB socket is located under the IO board on the UI loom Speaker The speaker is located on the rear of the front panel behind the UI by two M7 hex nuts and connected directly to the UI loom Air Filter Securing Magnet The air filter is secured in position by two magnets on the cavity assembly ...
Page 101: ...d repair manual 101 Fuses The fuse assembly F1 F2 F3 F4 F5 F6 is located to the front of the mains filters on the right hand side of the oven F7 is located next to the SMPS Note Specific fuse rating and function can be found detailed in the circuit diagrams Section 7 2 ...
Page 102: ... D16 Impinger Plate 1 2 E99 Filter override accepted VFD Bracket 2 8 E100 Mains supply switched on Component Resistances Waveguides 2 1 E101 Magnetron s failed on request EMI Filter L N 330kΩ Heating Element Wiring 2 0 E102 Heater on without request Cooling Fan 220Ω Mains Filter Wiring 1 2 E103 Ambient Overheat UI or IO 70oC Stirrer Motor 7 8Ω Magnetron 2 1 E104 Safety circuit open Overheat Thermo...
Page 103: ...t LH Mag overheat thermostat closed yellow LD10 12V supply to Aux circuits green OK LD15 Safety circuit Not used linked out yellow LD12 12V buss supply green OK LD17 Safety circuit Not used linked out yellow LD30 5V supply from onboard transformer green OK LD19 Run Yellow on off IO board functioning LD31 5V supply from onboard transformer green OK LD20 Status Rapid yellow flashing P Bus communicat...
Page 104: ...nd diagrams Back to contents 7 CIRCUIT BOARDS AND DIAGRAMS X512 X511 X510 X523 GND X524 X513 X500 X514 X500 X515 X402 X516 X532 X530 X413 X531 X534 X403 X535 X533 X517 X600 X540 X403 X541 X412 X518 X401 X200 X210 X101 X100 X410 X113 X112 X110 X411 X560 X519 X520 X521 ...
Page 105: ... SW3 for microwave circuit s X401 Wire 13 Neutral US L2 from F6 X402 Door Switch Interlock Wire 20 Live from door SW2 Wire 22 Neutral US L2 from door SW1 Wire 23 Live to door SW3 X403 Wire 26 Live from F5 X410 RH Rear HV Transformer Wire 31 terminal 0 Neutral US L2 Wire 35 terminal 200 208 Live Wire 36 terminal 230 240 Live X411 LH Front HV Transformer Wire 44 terminal 0 Live Wire 49 terminal 200 ...
Page 106: ...sed X518 Not used X519 Convection fan speed controller VFD signal Wire 66 red 0 10V Wire 67 green 10V Wire 68 blue GND X520 Not used X521 Not used X522 Not used X523 UI communication and power cable X524 Not used X530 Cavity temperature thermocouple X531 Not used X532 Not used X533 Not used X534 Not used X535 Not used X540 Not used X541 Not used X560 Not used X600 PM GND Chassis ground Note IO Boa...
Page 107: ...nual 7 Circuit boards and diagrams Back to contents 7 CIRCUIT BOARDS AND DIAGRAMS 7 2 Circuit diagrams conneX wiring diagram 50Hz 200 230V Door switches LV safety interlock circuit Overheat thermostats ELV safety circuit 1000W Ovens 2000W Ovens ...
Page 108: ...nd repair manual 7 Circuit boards and diagrams Back to contents 7 CIRCUIT BOARDS AND DIAGRAMS IO BOARD IO Board LV Connections Notes Standard power versions Centre Magnetron only X514 Link fitted X112 Pins 1 2 not used X411 Not used ...
Page 109: ...109 Merrychef conneX service and repair manual 7 Circuit boards and diagrams Back to contents 7 CIRCUIT BOARDS AND DIAGRAMS ...
Page 110: ...conneX service and repair manual 7 Circuit boards and diagrams Back to contents 7 CIRCUIT BOARDS AND DIAGRAMS Door switches LV safety interlock circuit Overheat thermostats ELV safety circuit 1000W Ovens 2000W Ovens ...
Page 111: ...nd repair manual 7 Circuit boards and diagrams Back to contents 7 CIRCUIT BOARDS AND DIAGRAMS IO BOARD IO Board LV Connections Notes Standard power versions Centre Magnetron only X514 Link fitted X112 Pins 1 2 not used X411 Not used ...
Page 112: ...112 Merrychef conneX service and repair manual 7 Circuit boards and diagrams Back to contents 7 CIRCUIT BOARDS AND DIAGRAMS ...
Page 113: ... cleanliness Switch the oven on and off with front switch allow to cool down 2 Check the power cord and plug for damage and replace if required 3 Remove the air filter and check for damage clean and insert or replace if required 4 Remove cook plate and check for damage clean and insert or replace if required 5 Inspect the 4 studs for signs of carbon and arching Remove the side panels and replaceas...
Page 114: ...Use the displayed oven serial number if this is invalid 15 In diagnostic view select operate each component to check operation as detailed in the visual view section 5 2 Check all speed ranges of the fans Record microwave individual combined current draws Record displayed Voltage Note ensure a bowl of coldwater is in the cavity for the microwave current draw checks 16 Exit out of visual view place...
Page 115: ...1 Check door seal condition and replace as required Replace every 24 Months or when damaged 12 Check door operation 13 Check on off switch operation 14 Check oven serial number firmware revisions Update firmware is older version s displayed 15 Check touch screen condition and operation 17 Check date time Update as required 18 Check and record oven counter screen 19 Check record amp draw heating el...
Page 116: ...neX service and repair manual Microwave Combination Oven Merrychef conneX Part Number 32Z9170 Version 1 2022 Welbilt UK Ltd except where explicitly stated otherwise All rights reserved conneX Service RepairMan_May 2022 ...
