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Welbilt Merrychef 32Z3923, Service & Repair Manual

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Welbilt Merrychef 32Z3923 Service & Repair Manual Download Page 92

 

 

Merrychef eikon

®

 e2s service and repair manual 

92 

_______________________________________________________________________________________________________________________________ 

_______________________________________________________________________________________________________________________________ 

6 Replacing components 

Back to contents > 

Mains cable entering the interior

 

 
 
 
 
 
 
 

(the mains cable gland is fitted to the cable inlet of the oven at the rear of the oven base) 

 

Catalytic Converters

 

 
See section 6.14 for convection fan motor assembly removal to access the catalytic converters. 
 

                         

 

 

Voltage Switching Relay(s)

 

 
The voltage switching relay(s) is located on the rear right hand side of the oven base by two M5.5 hex nuts. The 2000W e2s 
variant comprises two relays in the same location, one for each HV transformer. 

 

 
 

 
 
 
 
 
 

              

 

 

                

 

 
 
 

The upper catalyst is fitted using four M7 hex 
flange nuts, tightened to 2.1 Nm. 
 
Note: remove the storage cable ties before 
installing a new replacement catalyst. 
 
The lower catalyst, only installed on 2000W 
models, is again fitted using four M5.5 hex flange 
nuts, tightened to 2.1 Nm. 
 

Summary of Contents for Merrychef 32Z3923

Page 1: ...eikon e2s Service Repair manual Part number 32Z3923 Read instructions before use Microwave combination oven Date Feb 2021 v1 Models 50Hz 60Hz Language English ...

Page 2: ...nce for use and cleaning 13 2 9 Safe working when working on the appliance 14 2 10 Hazards and safety precautions during servicing 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 21 2 15 Process for discharging the ...

Page 3: ...ling fan 76 6 8 Replacing the QTS Quick Touch Screen assembly 77 6 9 Replacing the SRB Smart Relay Board 78 6 10 PM Personality Module replacement 79 6 11 Replacing the touchscreen control D and overlay 80 6 12 Adjusting the door microswitches interlocks 81 6 13 Replacing the stirrer motor and stirrer assembly 83 6 14 Replacing the convection fan motor 85 6 15 Replacing a transformer high voltage ...

Page 4: ...omers expectations the legal regulations and standards and our company s own reputation set the quality and service for all our 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...

Page 5: ...0W 1300W G 2200W 900W Power output microwave B 2000W High power version X 1000W Standard power version Voltage 30 230V MV5 220 230V 50Hz MV6 208 240V 60Hz 00 200V 20 220V Frequency 5 50Hz 6 60Hz Lead A Z 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 U USB Version A B A B pre prod...

Page 6: ...t follow the information in this document you risk potentially fatal injury and property damage To guarantee safety all people who 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 Form of warning n...

Page 7: ...5 Do not touch any internal wiring or connectors within the oven whether you believe it is live or not and avoid touching the metalwork casing panels etc of the oven 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 b...

Page 8: ...ations associated with handling heavy loads All servicing and repair work Working positions during servicing and repairs The service area for staff during servicing and 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 Mov...

Page 9: ...iant with EN 407 in European Union Safety boots Cleaning Activity Materials used Personal protective equipment Cleaning the cavity 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 ...

Page 10: ...ting condition of the microwave combination oven Do not operate the microwave combination oven unless it has been properly transported set up installed and placed into operation as indicated in section 6 of the eikon e2s 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 devic...

Page 11: ... disconnecting the electrical supply 3 Fire electric shock warning There is a risk of fire electric shock if the appliance is operated without respecting the minimum clearances 4 Hot surface warning There is a risk of burns from high temperatures inside the cavity and on the inside of the appliance door 5 Electric shock warning There is a risk of electric shock if the electrical power is not conne...

Page 12: ... from microwave energy leaking from the cavity Check the door seal regularly for signs of damage and replace it if required 4 Appliance 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 Chec...

Page 13: ...and also on 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 fr...

Page 14: ... Moving heavy loads WARNING Risk of injury from lifting incorrectly When lifting the appliance the weight of the appliance may lead 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 appli...

Page 15: ...asonable to work dead No person shall be engaged in any work activity on or so near any live conductor other than one suitably covered 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...

Page 16: ...hen servicing engage the parking brake on the wheels Risk of hands and feet being pinched Risk of electric shock from live parts 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 electric...

Page 17: ...d moving heavyweights Danger Where or in what situations does the hazard arise Preventative action Risk of injury from overstressing 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 ...

Page 18: ...ding all metallic accessories is connected to an equipotential bonding system Residual current device RCD The installation regulations 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 Disconn...

Page 19: ... a factor in nuisance tripping they should be avoided If the installation includes more than one appliance one residual current GFCI device must be provided for each 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...

Page 20: ...ing An equipotential bonding point is provided on the rear panel of the appliance for independent earth not fitted to US models GND connection Example phase loading diagram Loading per phase is not equal Therefore it is recommended to connect other electrical equipment to a separate L3 N from the mains supply _________________________________________ 208V Two Pole 240V Two Pole L1 L2 E L1 L2 E RED...

Page 21: ...ces WARNING Risk of burns from high temperatures 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 f...

Page 22: ...m 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 WARNING Risk of fire and or smoke Flames and or smoke may come out of the oven when switching it on after service repair This can be caused by a defective electrical component or ...

Page 23: ...ietary voltage tester is working correctly and prove the mains supply is dead 2 Wait 5 Minutes to allow the Capacitor to naturally discharge its energy It is recommended that you stand on electrically safe matting where possible Remove the lid and side panels to access the oven components Connect the Capacitor Discharge Probe s Earth clip to the Equipotential Bonding point at the rear of the oven ...

Page 24: ...ny 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 measures at every power switch to ensure that the power cannot be switched on again Always di...

Page 25: ...fore 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 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 f...

Page 26: ...g 114 lbs Safety clearances Right Left 0 mm 0 in Top Rear for ventilation 50 mm 2 in Electrical connected load ratings 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 Rated power consumption W 6000 2500 3300 6000 6000 Rated current per phase A 32 ...

Page 27: ...and they prove the oven door is physically closed or open The microwave circuit will not be energized if the door is open L2 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 F2 Check for continuity Check for prop...

Page 28: ...rectifying circuit on the SRB Primary Voltage 230VAC Secondary Voltage 24VAC 28VA 70o C Resistances Primary 81W Secondary 1 3W Check for opens shorts or grounds Check resistance of windings Check SRB connections X103 X103 1 X1 and fuse Check for lit LED s on SRB Check primary winding voltage Check secondary winding voltage On Off Switch On Off Switch PCB toggle Provides a 12VDC return to the Smart...

Page 29: ...ces a 3PH DC square wave frequency output Provides an DC 3 phase switched mode drive to the AC convection motor and is controlled by a 0 5 VDC signal from the relay board SRB The frequency output allows the Main Blower Motor to run at variable speeds 1ph power supply Control Signal Voltage 5VDC output to SRB 1 5VDC return to determine speed percentage of convection fan motor 1 3 7VDC on 16A 13A ov...

Page 30: ...ve Switched Voltage 12VDC Resistance if open O L if closed 0W Opens at 300o C 570o F 310o C cavity temperature Check continuity through switch Check for 12VDC on both sides of switch Terminals are normally closed if open reset thermostat and test oven for proper operation Check SRB connections plugs on X18c X18d X18e Check convection fan motor IP Check SRB LED Magnetron Limit Stat s Automatic rese...

Page 31: ...tion 5 8 for further rating information 208 240 VAC see note 2 Follow all test procedures in Section 5 8 Check for opens shorts grounds Check SRB connections X4a X102b X102a Check SRB LED Check Error Log for E101 E113 events HV Capacitor s One HV Capacitor fitted as standard two HV Capacitors fitted to High Power oven versions Internal discharge resistor In conjunction with the HV Diode s to doubl...

Page 32: ...ds K Type Junction at 25o C ambient 1VDC 1 000mVDC o C mVDC F o C mVDC F 0 C 0 32 F 125 C 5 1 257 F 25 C 1 77 F 150 C 6 1 302 F 50 C 2 122 F 200 C 8 1 392 F 75 C 3 1 167 F 250 C 10 2 482 F 100 C 4 1 212 F 300 C 12 2 572 F Note 1 12A fuse F3 used in Americas Note 2 208 240 HV Transformers used in most 60Hz applications Note 3 0 95µF Capacitors used in most 60Hz applications 1 0µF Capacitors used in...

Page 33: ...lopment Mode enables multistage cooking profiles to be developed then stored under a name and symbol for reuse Manual Mode enables multistage cooking without the need for a pre programmed cooking profile Press Go Press Go allows quick access to use the cooking profiles that are already stored Cookbook Cookbook contains the cooking profiles stored in the memory of the appliance It displays favourit...

Page 34: ...tton Meaning Function Keyboard screen The keyboard screen is used to enter an authorised password to enter data for programmes and may restrict operator access to some functions Clear screen Select the clear screen key to delete text from the keyboard screen Keyboard Type in text using the keyboard Spacebar Select the spacebar key to insert a blank Return Select the return key to start a new line ...

Page 35: ...e back the base and the oven door Avoid the roof and door seal 5 For difficult areas leave to soak for 10 minutes with the oven door open Clean the cavity using a non abrasive sponge Again avoid the roof and do not scrub the door seal Do not spray directly into the cavity Avoid the roof and door seal IMPORTANT Cool down the oven before cleaning You will need PPE heat proof gloves protective rubber...

Page 36: ... be closed by the cover USB programs Menus IMPORTANT Downloading from a USB memory stick will clear all the existing programs in the memory of the appliance Check that the key has the correct number code for the programs you want to load into the memory and the automatic update file 1 cbr autoupd ate 1 Switch the appliance OFF 2 Open the cover to the USB port on the control panel 3 Plug in the USB...

Page 37: ...X XX bin XXX XXX XXX_e2s_SRB_APP bin VX APP e2s cbr icon file autoupd ate for auto update only Ensure USB memory stick is ejected from computer after loading files not just unplugged as files may be corrupted Do not attempt to read firmware files on a computer as files may be corrupted Only use the Menuconnect operating program to read menu files on a computer as files may be corrupted The USB mem...

Page 38: ...xxx xxx bin xxx xxx xxx_e2s_SRB_APP bin Vx APP e2s cbr Latest menu xxxxxxxxxxxxx cbr autoupd ate Load only the correct complete menu file onto the USB memory stick and not a single cook menu 1 Load the USB stick with the autoupd ate file Copy the following firmware files to the ROOT directory of the USB memory stick QTS e2s Vxxx xxx xxx bin xxx xxx xxx_e2s_SRB_APP bin Vx APP e2s cbr Menu cbr if re...

Page 39: ...ave to be reloaded on replacement of the QTS PM Procedures as covered in this section 4 5 should be followed See section 6 10 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 firmware loaded without the autoupd ate file 2 Switch on the oven and tap...

Page 40: ...ps operating during the process After 100 various screen displays appear as the software reboots 4 Once rebooted check if the screen shows the correct QTS version UI Ver If not repeat the process using the correct file 5 Remove the USB memory stick and keep it in a safe place 1 When you select firmware the current QTS Quick Touch Screen and SRB Smart Relay Board firmware versions are displayed at ...

Page 41: ...R file e2s icons Note A tinted band over a file name indicates the file is not valid for your oven 3 Check if the file information shown is correct before selecting OK If not select X and locate the correct file 4 The file update progress is displayed When the application icons file download has been completed the oven will reboot and display a flash screen as it updates the cooling fan stops oper...

Page 42: ...al on the appliance before switching on 5 Check the display 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 Touchscreen calibration 1 Apply continuous light pressure to the screen while ...

Page 43: ..._________ 5 Service information Back to contents Enter service mode 1 On start up tap the top right of the splash screen to bypass preheat of the cavity 2 Enter the authorised user password for example MANAGER on the keypad Select OK green tick to display the Settings menu 3 Select the spanner symbol 4 Enter the service password For example SERVICE on the keypad Select OK green tick to display ser...

Page 44: ... components using Visual view 5 Check the Temp Comp to enter the oven cavity temperature calibration mode 6 Use the down arrow to access more options 4 Check the Demo Mode to switch between normal operation and demonstration only operation 7 Check to perform the tests of your microwave combination oven as described in the Testing selected components section 5 6 of this manual If required refer to ...

Page 45: ...SRB version information are also displayed below 2 Clear the error message by switching the oven Off and then back On or by power cycling the mains power supply to the oven See section 5 3 for error code list 1 Enter settings menu and select the USB symbol The USB screen appears 2 Open the cover of the USB port and insert the USB memory stick into the slot NOTE The USB memory stick may take severa...

Page 46: ...o display a listing of oven component errors events 2 Scroll down the list if necessary and select an error from the list to display individual records 3 Error details include component description error caused date and time of the error with details of failure and range 4 Select backspace to return to the list again to return to the service menu 1 Select Oven counters to display the filter door c...

Page 47: ...se the door and check the colour of the door symbol on the display 5 Select the cooling fan and check if it is operating correctly Repeated presses will increase the fan speed noticed by an increase in the fan noise volume and air flow through the filter off 30 50 85 100 off 6 Place a microwave safe container of water into the cavity and close the oven door Select a magnetron to test operation and...

Page 48: ... a preheat temperature choice Once preheated the oven displays the main menu if in Full service mode or a recipe selection if in Quick service mode Shutting down sequence When the oven switch is turned OFF the screen displays Shutting down and the microwave and heater safety relays de energise The cooling fan and convection fan operate until the cabinet temperature has been sufficiently reduced to...

Page 49: ... at a time Voltage too low below 10 of nominal voltage There may not be enough voltage to start the magnetron If the above did not resolve the issue check all the LV connections are tightly fitted from the incoming power supply through the Filter Fuse F2 Door Switches SRB board and from the SRB board to the HV transformer s The connections on the HV side from the HV Transformer through the Capacit...

Page 50: ...ats are typically caused by a lack of cooling Check the board temperatures in the error log to determine the cabinet air temperature at the time of the failure Check the magnetron cooling fins heat sink are clean and free from dust debris and grease build up clean as required Sufficient cooling is required please ensure all panels are fitted correctly and do not have any cooling leakages from arou...

Page 51: ...e control boards E111 CAVITY SENSOR Cavity thermocouple damaged or unplugged No temperature rise registered for 10 minutes during heating Check that the thermocouple is correctly fitted and secure on to the SRB If the thermocouple generates erratic values or is more than 25o C out of range it will need to be replaced if the connection is in good condition and intact If the fault reoccurs after rep...

Page 52: ...key press Pressure registered for 5 seconds on QTS screen Check touch screen overlay see E087 E083 SRB VERSION Incompatible SRB version Replace SRB check part numbers E084 INVALID DATE Invalid date at start up Set correct date and time E087 CONSTANT KEY PRESS DETECTED Pressure registered for 15 seconds on QTS screen Oven will stop working Ensure the firmware is up to date with the most recent upda...

Page 53: ...there should be no microwave leakage and corrections should be made if any leakage is detected above 0 5mW cm2 Check for damaged cavity thermocouple Information Error Codes Error Problem Solution E000 OK Communications have been established between the SRB QTS boards Solution not required if event recorded after mains power has be supplied to the oven E100 or during successful firmware updates Che...

Page 54: ...ace door switches Check door switches are adjusted correctly Check oven door hinges are fitted working correctly Check all wiring and connections Check L2 is present on twin phase ovens Continuous key press Oven not operational displaying constant key press message See E087 Shutting down Oven shuts down randomly during operation Check on off switch wiring and connections Replace on off switch Cook...

Page 55: ...tice is to advise on this testing in addition to the following instructions as deemed necessary If the customer requires PAT testing of the Merrychef equipment we suggest this is limited to a earth continuity and b insulation resistance measured at 500 V DC All Merrychef commercial combination microwave ovens are classified as CLASS 1 for the purpose of testing Should it still be deemed necessary ...

Page 56: ...icrowave power test measuring the microwave power output of the magnetron s Check that the following requirements have been met The appliance is cool NOTE The power output is established under IEC 705 standard method which is only workable in laboratory controlled conditions The power output is also affected by line voltage under load so this test is an approximation only 1 Connect the mains lead ...

Page 57: ...ection fan at 10 7 When the countdown has finished remove the container from the cavity Immediately stir with a plastic implement and measure the water temperature 8 Calculate the temperature rise of the water end temperature minus the start temperature The temperature rise should be 14 3 C 25 7 F 10 for the 1000W 1 magnetron variant The temperature rise should be 28 5 C 51 4 F 10 for the 2000W 2 ...

Page 58: ...a heat sink 1 Place temperature probe in the centre of cavity 2 Ensure the oven is in Full Serve Mode green ticked box and not in Manual Mode red ticked box 6 When the microwave leakage test stops after 30 seconds change the water and re select the test to continue 7 Select the red X on the display to stop the test at any time 8 Readings must be below 5mW cm ideally zero as there should be no micr...

Page 59: ...played prefixed with 12 Compare the displayed temperature with the actual temperature shown on the digital thermometer Recalibration will be required and should be carried out swiftly if the readings are outside the following guidelines Model Preheat Display Thermometer Action e2s 250 C 250 C 246 C or higher Recalibrate 239 C or lower Recalibrate 240 C to 245 C No action required 13 To recalibrate...

Page 60: ...rformed following the completion of a service or repair to ensure that the appliance is working correctly before handing back to the customer Some of the tests have a countdown timer where failing to carry out a test within the time limit will cause a test failure and the recommission test will have to be restarted If the recommission test tab is greyed out the oven is above 200 C and will not all...

Page 61: ...4 High Voltage winding approx 57 Ω 5 Filament winding between terminals less than 1 Ω 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 Complete the following checks after the oven has been serviced repaired tested before connecting to the mains electricity power supply 1 All intern...

Page 62: ...the mains power supply High voltage capacitor test 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 work See section 2 15 How to discharge the e2s ...

Page 63: ...en the oven is on NEVER make any electrical measurements on the high voltage circuits including the magnetron filament whilst the oven is connected to the mains power supply 3 Connect the DMM to both terminals of the high voltage capacitor The test is passed if the DMM display reads approx 10 MΩ 4 Connect the DMM to one terminal and the metal outer case of the high voltage capacitor The test is pa...

Page 64: ...en Approx 1400 rpm 10 1V Door closed not cooking Approx 2500 rpm 31 1 8V Door closed heating up or Shutting Down Approx 3500 rpm 50 2 5V Door closed cooking speed as specified by program or setting up to a maximum of 7000 rpm 100 5V Convection fan motor speed controller LED status display The VDF contains two diagnostic indicators LEDs to display the drives operational status LED Drive Status Colo...

Page 65: ...discharged before commencing work Anti static precautions have been taken The casing of the appliance has been removed Check the following 1 All associated wiring and connections from SRB X3 X9 through the speed controller to the convection fan motor 2 Convection fan motor thermal cut out IP two grey wires 3 Convection fan motor rotates freely not seized 4 Convection fan motor winding resistances ...

Page 66: ...nts 5 10 Optional components casing removed Kitchen Connect Control Module KCCM Optional Ethernet WIFI communications module for remote connectivity through KitchenConnect Installed on the inside of the rear panel and connected to the SRB X12 X13 KCCM Module LED Colour Information LED1 Red 12VDC power from SRB LED2 Orange 5VDC power for additional components LED3 Orange 5VDC power LED4 Yellow 3 3V...

Page 67: ...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 wrench nut runner M5 5 hex open ring spanner M7 hex socket wrench nut runner M7 hex open ring spanner M8 hex socket wrench nut runner M10 hex socket wrench n...

Page 68: ..._______________________________________________________________________________________ _______________________________________________________________________________________________________________________________ 6 Replacing components Back to contents View right hand side View rear side ...

Page 69: ...ot air fan motor The convection fan motor is controlled by the speed controller and drives the convection fan for air flow within the oven cavity 17 Exhaust pipe The exhaust pipe leads excessive steam from the cavity to the cooling duct and the rear air outlet of the oven 18 Cooling duct The cooling duct directs heat generated by the magnetron s to the rear of the oven 19 Transformer low voltage S...

Page 70: ...panels of the casing ensuring all 5 5M bolts are refitted and 1 The side panels have been correctly slotted into the front cavity and base plate 2 The top panel pins have been correctly slotted into the front and side panels 3 If fitted ensure the power coms lead is reconnected to the module KCCM 4 No wires have been trapped 1 Remove top panel first Unfasten the three M5 5 hex head flange bolts at...

Page 71: ...assembly 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 Additional PPE Mask Gloves for handling insulation material 2 Fully open the oven door Insert the metal pins into the corresponding holes each door hinge as m...

Page 72: ... door to the cavity correctly 1 Refit the door to the oven with the insulation and door skin removed 2 Close the door 3 Loosen the four M8 hex bolts holding the door hinge assemblies and push the door squarely against the cavity Whilst holding the door in this position tighten the four M8 hex bolts 4 Remove the door from the oven and refit the insulation and door skin 5 Refit the door to the oven ...

Page 73: ...aken to ensure the power cannot be switched on again The appliance is cool 1 Place a Stanley retractable knife blade underneath the door seal and go all the way to break the seal Ensure you do all four sides avoiding the metal clips on each corner Please ensure all safety aspects are adhered to while working with a sharp knife 2 Gently pull the metal clip out of each corner and lift off the door s...

Page 74: ...annot be switched on again The appliance is cool The top left and right panels of the casing of the appliance have been removed The high voltage capacitors are discharged before commencing work The magnetron s is are located on top of the cavity and is are fixed to the cooling duct and the cavity roof The 2000W e2s variant comprises two magnetrons located on the left and right hand sides of the co...

Page 75: ...he right side of the cooling duct seen from the outlet of the ducting 1 The new magnetrons come with four pressed studs for fixing These studs need to be removed before fitting the magnetron to the oven NOTE The studs can be removed by knocking them out of the tabs with a hammer Ensure the tabs are not bent during this process Secure them by laying them upon a piece of tube while pushing out the s...

Page 76: ...y seated Fit all of the M8 bolts loosely then tighten in a cross pattern to ensure the magnetron seats evenly WARNING Ensure nothing becomes trapped under the magnetron mounting points e g insulation material while fitting the magnetron This can lead to microwave leakage NOTICE If the electric connections have not been restored properly this may lead to malfunction damage of the oven 6 7 Replacing...

Page 77: ...ge bolt under the plastic front facia Control D 1 Unplug the electrical connection of the cooling fan on the right hand side of the appliance 2 Loosen the two M7 hex nuts each securing one arm of the sheet metal bracket which holds the cooling fan Then turn the bracket clockwise 3 Twist and remove the cooling fan via the left hand side of the oven when looking at the oven from the front Top sectio...

Page 78: ...unction damage of the oven 6 9 Replacing the SRB Smart Relay Board Component 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 side and top panels of the casing of the appliance have been removed The high voltage ...

Page 79: ...mware and the error log file 1 Unplug the old PM from SRB and fit replacement PM ensure part number is correct 2 Refit all oven panels plug in oven and switch on 3 Tap the screen to hold and check the SRB and QTS UI versions are the latest release If not execute a firmware update using the latest versions See section 4 5 for details 4 Recommission the oven in service mode Fitting the QTS Personali...

Page 80: ...e the selection is correct before confirming by the green tick This is imperative as it changes the oven functions based on the selection Once confirmed the oven serial number and power selection cannot be changed without replacing the QTS PM again 6 Tap the screen to hold and check the SRB and QTS UI versions are the latest release If not execute a firmware update using the latest versions See se...

Page 81: ...cuit if the primary SW3 fails The monitor microswitch SW1 located on the right hand side of the oven inner will short out the microwave circuit blowing the F2 fuse if both secondary microswitch SW2 fails IMPORTANT In the event that the monitor switch SW1 causes the microwave circuit F2 fuse to blow the secondary SW2 and monitor SW1 microswitches must be replaced due to exposure to high short circu...

Page 82: ...lace the green 2mm spacers with the two red 4mm spacers Then carefully close the door ensuring the spacers are still in position 5 Slacken the pivot nut using a M7 hex socket wrench 6 Release the adjusting M7 nut and move the backplate until microswitch SW2 just activates closes Then tighten both nuts 7 Remove the spacers then open and close the appliance door 5 10 times ensuring the door switches...

Page 83: ...nnected 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 and side panels of the casing of the appliance have been removed The high voltage capacitors are discharged before commencing work 1 Loosen the two M7 Hex Screws at the rear and unfasten two M5 5 hex head flange bolts at the front to remove the jet imp...

Page 84: ...jet impinger plate screws to NO more than 1 8 Nm of torque 4 Remove the partition plate from the cavity NOTE The partition plate features a rubber gasket on the side pointing upwards to the stirrer when mounted The rubber gasket prevents grease laden air from soiling the stirrers and needs to be intact at any time 5 The image shows the 1000W e2s variant equipped with one stirrer stirrer motor The ...

Page 85: ...e cavity There are three nuts close to the horizontal edges and two nuts close to the vertical edges Carefully cut the tape covering the insulation mat with a knife to access the nuts and plate seam Unfasten the ten M7 hex nuts to remove the plate with the convection fan motor assembly being careful of the wiring in the vicinity Note Do not unfasten the four M13 bolts securing the convection fan m...

Page 86: ...nsformer high voltage Component Tools required M8 hex socket wrench Discharge Tool On replacement ensure the rear plate is placed fully over the mounting points on the cavity before refitting and tightening the nuts fitting new rubber gaskets when refitting the replacement motor assembly and vent pipe ensuring the mating surfaces are clean 1000W e2s variant one high voltage transformer feeding the...

Page 87: ...d properly this may lead to malfunction damage of the oven On the 2000W ovens the HV transformers are wired out of phase with each other i e Neutral to the zero tapping on one HV transformer Live to the zero tapping of the other HV transformer 6 16 Removing the convection fan motor speed controller Component 1 Unplug all the electrical connections on the transformer s 2 Disconnect the transformer ...

Page 88: ...hex nut fixing the wiring connection Follow the same procedure re connecting the wiring and tighten to 2 Nm 1 Unplug all electric cables connected to the convection fan motor speed controller 2 Unfasten one M5 5 hex head flange bolt at the top of the bracket to detach the convection fan motor speed controller 3 Refit in reverse order refitting the top securing bolt and reconnecting the cables to t...

Page 89: ...will cause the switch to open and break the safety circuit to the SRB 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 The cavity high limit cavity overheat thermostat can be accessed via the rear panel on the left hand side of the grille to manually reset Re...

Page 90: ...riv PZ2 screws Steam Vent Exhaust pipe Two EMC filters fitted Heater Microwave Wiring connected by M7 hex nuts EMC filter to bracket by two M7 hex nuts EMC filter bracket to base plate by two M7 hex nuts slotted in at the back Three filters fitted to JP models Two on the filter bracket and a third to the left of the HV Transformer for the VFD supply see wiring diagram in section 7 2 for further in...

Page 91: ...e Cavity temperature measuring is done by a temperature sensor thermocouple connected to the SRB The thermocouple is fitted in the rear of the cavity from the left hand side sealed with a gasket and held in place by a M7 hex nut The low voltage transformer ELV is located on the cooling duct on the left hand side of the oven fitted by four M5 5 hex head flange bolts The high voltage capacitor is lo...

Page 92: ...t the rear of the oven base Catalytic Converters See section 6 14 for convection fan motor assembly removal to access the catalytic converters Voltage Switching Relay s The voltage switching relay s is located on the rear right hand side of the oven base by two M5 5 hex nuts The 2000W e2s variant comprises two relays in the same location one for each HV transformer The upper catalyst is fitted usi...

Page 93: ..._____________________________________________________________________________________ 6 Replacing components Back to contents Air Filter Microswitch Speaker The speaker is located on the top front left hand side of the cavity frame by two M7 hex nuts and wired directly to the QTS The air filter microswitch is located on the bottom front left hand side of the cavity frame by a M5 5 hex nut and wire...

Page 94: ...0 Recommission test failure convection fan Magnetron 7 8A Cavity Overheat Thermostat 0 7 E91 N A for e2s Recommission test failure turntable Panels 2 1 E92 Recommission test failure heater 1A Circuit Breaker Ratings Partition Plate 2 1 E93 Recommission test failure magnetron s 5A e2s 1ph 1000W D16 Stirrers 1 0 E94 Recommission test failure air filter e2s 1ph 2000W D32 Impinger Plate 1 2 E95 Recomm...

Page 95: ...e 1 7 E108 Missing or corrupt QTS PM HV Transformer Sec 57W LV Transformer 2 1 E109 Missing or corrupt SRB PM Capacitor 10MW Steam Vent Pipe 2 1 E110 Incompatible SRB firmware Front Panel 2 1 E111 Cavity sensor open circuit Maximum Cavity Temperature Mains Filter to Bracket 2 8 E112 SRB temperature sensor failure 275oC Fuse Holder 1 0 E113 Magnetron s on without request 1A VDF to Bracket 2 8 E115 ...

Page 96: ...e outputs from inboard transformer Relay and triac lit to show that a signal has been sent to energise that component Door switches lit to show door closed Overheat thermostats lit to show safety circuit closed LED positions Item Name 1 Cooling fan Yellow LED Flashing Solid at 100 fan speed 2 Convection fan Yellow LED Dim 10 50 Bright 60 100 fan speed 3 Stirrer s Yellow LED 4 5V supply Green LED 5...

Page 97: ... temperature sensor thermocouple 9 X5 not used 10 X13 RJ11 P Bus ethernet port optional kitchen connect 11 X12 RJ12 C Bus development PC port optional kitchen connect 12 X11 RJ45 P C Bus QTS cable 13 X1 24V supply from low voltage transformer Wires 18 19 14 X8 cooling fan Wires 58 59 15 X17 not used 16 X20 microwave stirrer s Pins 3 4 not used on 1000W ovens 17 X9 mains output convection fan contr...

Page 98: ...hat the board has booted up P Bus Yellow LED irregular flashing indicating data communication with SRB C Bus Yellow LED pulsing 0 5 second flash lit to show data being loaded from the Personality Module PM onto the QTS Note Bus LED operation alters during download and uploading from a USB memory stick LD5 Yellow LED lit to show the QTS is reading the USB port or that a USB memory stick is fitted Q...

Page 99: ..._____________________ _______________________________________________________________________________________________________________________________ 7 Circuit boards and diagrams Back to contents 7 2 Circuit diagrams e2s wiring diagram 50Hz 200 230V Door switches LV safety interlock circuit Overheat thermostats ELV safety circuit 1000W Ovens 2000W Ovens ...

Page 100: ...tted on the 1000 watt 2000 watt oven Diode HV07 16 42 43 41 240 208 0 31 NC 37 38 30 36 35 30a 60Hz T2 Transformer Left Hand Side From The Front Magnetron 1 Right Hand Side From The Front Diode HV07 16 56 57 55 240 208 0 50 49 44 NC 51 52 45 45a Magnetron 1 Overheat Stat M L N Stirrer Motor 1 Connected to X20 Pins 1 2 On SRB 11 29 Heater 2 2kW M L N Stirrer Motor 2 fitted on 2000 watt oven only Co...

Page 101: ...________________________________________________________________________________ _______________________________________________________________________________________________________________________________ 7 Circuit boards and diagrams Back to contents e2s wiring diagram 50Hz 200 230V continued ...

Page 102: ...________________________________ _______________________________________________________________________________________________________________________________ 7 Circuit boards and diagrams Back to contents e2s wiring diagram 60Hz 208 240V Door switches LV safety interlock circuit Overheat thermostats ELV safety circuit 1000W Ovens 2000W Ovens ...

Page 103: ...t oven Diode HV07 16 42 43 41 240 208 0 31 NC 37 38 30 36 35 30a 60Hz T2 Transformer Left Hand Side From The Front This microwave circuit is only fitted on the 2000 watt oven Magnetron 1 Right Hand Side From The Front Diode HV07 16 56 57 55 240 208 0 50 49 44 NC 51 52 45 45a Magnetron 1 Overheat Stat M L N Stirrer Motor 1 Connected to X20 Pins 1 2 On SRB 11 29 Heater 2 2kW M L N Stirrer Motor 2 fi...

Page 104: ...________________________________________________________________________________ _______________________________________________________________________________________________________________________________ 7 Circuit boards and diagrams Back to contents e2s wiring diagram 60Hz 208 240V continued ...

Page 105: ...____________________________________________ _______________________________________________________________________________________________________________________________ 7 Circuit boards and diagrams Back to contents e2s wiring diagram 200V JP Model Door switches LV safety interlock circuit Overheat thermostats ELV safety circuit ...

Page 106: ...________________________________________________________________________________ _______________________________________________________________________________________________________________________________ 7 Circuit boards and diagrams Back to contents e2s wiring diagram 200V JP Model continued ...

Page 107: ...________________________________________________________________________________ _______________________________________________________________________________________________________________________________ 7 Circuit boards and diagrams Back to contents e2s wiring diagram 200V JP Model continued ...

Page 108: ...iquids 1 Check the oven for obvious signs of damage and 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 1 Pre Jan 2019 Remove old cook plate verify the PTFE feet are intact if not replace with new angled edge at the fr...

Page 109: ...lect the oven counters and reference the service check sheet for recommended replacements advise the customer on actions required 14 Select the visual view to perform individual component checks 15 In visual 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 and heater current draw...

Page 110: ...ck on off switch operation P P P P 14 Check oven serial number firmware revisions P P P P Update firmware is older version s displayed 15 Check touch screen condition and operation P P P P Calibrate if required 16 Check touch screen overlay and replace as required P P P Replace every 24 Months or when damaged 17 Check date time P P P P Update as required 18 Check and record oven counter screen P P...

Page 111: ...rwise All rights reserved HOELOW R HUV IXOO LQWHJUDWHG NLWFKHQ V VWHPV DQG RXU SURGXFWV DUH EDFNHG E LWFKHQ DUH DIWHUPDUNHW SDUWV DQG VHUYLFH HOELOWȇV SRUWIROLR RI DZDUG ZLQQLQJ EUDQGV LQFOXGHV Cleveland Convotherm Crem HOȴHOG ȴWNLWFKHQ Frymaster Garland ROSDN LQFROQ 0DQLWRZRF 0HUFR 0HUU FKHI DQG 0XOWLSOH Bringing innovation to the table ZHOELOW FRP e2s Service RepairMan_Feb 2021 ...

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