Service Manual - Whaley Food Service
Contents
1. 4 F IE EE T DE Ed 2 em UCI Mealstream 401 3273311 Issue 9 Page 40 Circuit diagram 1003 XX52 Twin Phase Before August 2004 ea te is Ie Glee2. f EE NT Mealstream 401 3273311 Issue 9 Page 41 APPENDIX 1 MenuKey Download Procedure The MenuKey System automatically changes all the cooking programs on the numbered icon pads with the turn of a key To change the menus on the oven 1 Ensure the power switch is off 2 Liftthe MenuKey cover in the front panel of the oven and put the key in the keyhole Turn the key clockwise to the stop 74 turn Do not remove the key at this stage i E x NU 3 Switch the power switch on The oven will now go through the program download sequence by ds displaying the following minutes seconds example Key C02 The Key Code The number of programs and each program number on the key minutes seconds example 27 Programs Ea LE When the display shows 00 00 remove the key and close the cover
3. gt GE ON OT Lo e AE mm H LOE 1 3503 se 0 assy es N amog H 1 N 4 N 1 po ch SA A V 12 N c Ex Nys 7 H Y BENNI ADLLDS 1331 cd 5 aly x E b i 4709 amp 04 015153 1591 1305 NEES ie ra zlkelslolel le be oe 61 E ET 3sn4 N 07e NSWAOASNVAL 851 AN VA 35v17D AOT ERIS TIa Er WH 831114 e ion eon E ATE La E FT T EE 7 N ID ON ILYOHS s 2 A 5 T Ee 27 EIND ISN NUISE3A o_o ALUMS LOD 102 S6 m HOL MAS AN THD TS ii INSW373 BH31v3H 39 INH 350 NOISMAA 33 TE MAS LV 3H83AU A Avo Hlava Page 39 Mealstream 401 3273311 Issue 9 Circuit diagram 1003 5 Single Phase Before August 2004
4. aa i 3 NOLLOSANOO COT 1 1 WANEN SOLON TEV LiL L INA 9NTIG00 I WOE vel NOS bs RE SANT F 1 i 15508005 zi i ESEL 5 IMIS Date 08 2004 40H0090 Issue 3 Page 37 Mealstream 401Ovens 3273311 Issue 9 CD2 it diagram RMC 1003 ircui C ONIHIM ZOD LOP INV3S LLS TYAN Ut NVA WWOR 2 HOLIMS LV3HS3AO ALIAVO ZN S eo mI I a HOLIMS SNIVA TVHIRSN E WIEN id a MaMOd dy DEE 5 BVEMOND WOLLOB a SAT EN AMYONO23S Le YANNI WOLLOH M YOO EN v TA NA Gn Au WIS C 1337901 om n 7 on 2 aasn LON Il di
5. 1391 1305 5 4 9709 4 027 14915 1408 HANNI WOLLOH 1391901 48 NOLLISOd SS N3do dalli Date 08 2004 40H0169 Issue OON Nan 20000 ALIAVO 9 HANHOASNVAHL JIHATNI 25067 ONILYOHS ALIAVO 110 115 NOSISNOVIA HOLIMS LHOI JOL 95 EL 23604 21 dalli On on AN INSAGTS 36 Mealstream 401Ovens 3273311 Issue 9 CD2 it diagram RMC 1003 ircui C aan INVOVIO ONIHIM E09 LOP INV3S LS Hia add mO 1 ER Voed wann 8 19915 2 LE OAN SJSN LINDHID HALVAH TIY WALNAN LENS Ww by WEITEN HOLIMS LVSHYSAO ALIAVO AAT 18 sod RENEE WANEN HYSMOHS ER ANDES HENN AOLLOS 3 Y SONE ood AHOHAOL
6. 1 uo 999 NG NOLLO3ANOO 9 I A EET SAT WETEN An Ap ad T Q D Qn NVA 1502 6 m SAdANIHO 12815 TA ivis OV al ScvOZLE cnn Sis SASN YALVAH 1 5 SAT 1 EE 5 Luvs VOE NOs ANIT vel SAT kd T Y amp E 138 HIMOd SAT ud e 2 4 135 dWaL 1 WaL ALIAVO i TENEN MOSNSS wo NEY Zec00HLL 38 Mealstream 401Ovens 3273311 Issue 9 XE Before August 2004 RMC 1003 5 EE amp RMC 1003 ircuit diagram C
7. Mealstream 401 3273311 Issue 9 Page 18 Oven door assembly Solid door assembly Silver MC3230X02 Solid door assembly Black 11H0071 22 22 38 39 40 40 41 42 43 44 46 47 48 52 53 Solid Door Assy Silver Solid Door Assy Black Door Handle Silver Door Frame A Black Door Cover Outer Silver Door Cover Outer Black Inner Panel Door Reinforcement Door Frame B Insulation Wrap Door Base Silver Door Cover Plate Door Switch Packing B Door Rear Plate 11H0031 11H0071 RBR1285048 MC30503 40H0080 40H0082 40H0081 RMC70722 MC3055 3270001 MC3031KX04 MC3064 MC3056 MC3065 MC3066X01 Mealstream 401Ovens 3273311 Issue 9 Page 19 Magnetron and door interlock components Model RMC1003 EES Model RMC1003 5 If replacing a Sanyo Magnetron with a Panasonic Magnetron the HV capacitors need to be changed XE amp EE models 1 1 to 1 0uF 3021241 54 55 56 57 58 59 60 61 Door Switch Bracket Primary Microswitch Low Voltage Microswitch Secondary Microswitch Monitor Microswitch Microswitch Insulator Outlet Duct Foam Tape 40H0023 3070240 3070240 3070240 3070240 3120115 MC3037 3120042 62 63 64 65 66 67 68 Inlet Duct Magnetron Cut out Switch Bracket Blower Assembly M3 x 25 Pan Head Pozi M3 x 30 Pan Head Pozi RMC7
8. Mealstream 401 3223311 Issue 9 24 Components RMC1003 5 XE5 75 Diode Assembly 11H0010 88 Transformer Top Bracket MC3127 89 HV Lead Assembly Ferrite 11H0025 90 Transformer 208 240V 50Hz 3071233 90 Transformer 208 240V 60Hz 3071230 50Hz EE XE 3071331 x1 1 0uF 2500V 91 HT Transformer Bottom 40H0070 CD2 XD2 92 Capacitor Band RMC7215 93 Filter Bracket 40H0065 94 HT Transformer Support MC3024 Bracket Transformer replacement see Appendix 3 Mealstream 401Ovens 3273311 Issue 9 Page 25 amp principle components Models RMC1003 XX5 RMC1003 2XX52 76A 90 90 102 128 128 130 132 Capacitor Clip Transformer 208 240V 50Hz Transformer 208 240V 60Hz Resistor 470R 50W Gold Cooling Fan 230V 50Hz Cooling Fan 230V 60Hz Diode Board Heater Relay 3071237 3071233 3071230 3070283 3071128 3071190 11H0058 3070986 Transformer replacement see Appendix 3 Oven Type Capacitor Part No 50Hz XX5 3071329 x2 60Hz XX5 3070385 x1 3071329 x1 Mealstream 401 3273311 Issue 9 Page 26 Electronic control panel assembly D 9 Membrane Panel a z um mm 2 Membrane Panel Menukey Starbucks Blue Red Grey Model Membrane Assy Logic PCB 5 XE5 XX5 11H0060 11C0285 XX5 Starbucks 11H0024 11C0285
9. 650mm 4 950mm 625mm 400mm 100mm NEVER Install an oven above fryers grills griddles or any other major heat source NEVER Stack machines on top of each other always use a double stand ALWAYS Place containers in the cavity carefully impact damage may chip the vitreous enamel coating Mealstream 401 3223311 Issue 9 6 Electrical installation WARNING This appliance must be earthed Failure to do so may result in electric shock and death All models 30A must be connected to a separate electrical supply rated at 30 Amps by a qualified and approved electrician A suitable 30 amp rated isolating switch with a 3mm contact gap on both poles should be fitted for each oven installed Establishments with standard Type circuit breakers are sensitive to surges which occur on switching on freezers refrigerators and other catering equipment including microwave ovens Because of this we strongly recommend that a separate Type C circuit breaker designed specifically for this type of equipment must be fitted An individual suitably rated circuit breaker should be fitted for each oven installed Models RMC1003 EES 1003 CD2 The power outlet used must be individually fused It is essential that the socket is properly installed and GREEN earthed It should be fed from a circuit which is amp YELLOW suitable for high power electrical appliances and it is important that this ci
10. sss 19 Magnetron amp Door Interlock Components 20 Magnetron amp Door Interlock Components 21 Major Electrical 5 22 Input Wiring Filters and FUS S 23 Input Wiring Filters and 2 24 AT Components bred 25 HT Principal components RMC1003 XX5 XX52 26 Electronic Control Panel Assembly 27 Manual Controls Panel 28 Membrane Panel 29 Complete Spare Part 30 31 Circuit Diagrams 32 38 Appendix 1 MenuKey Download Procedure 39 Appendix 2 Cleaning 40 Appendix Transformer Replacement eenen 44 Manual corrections and modifications 45 Merrychef Limited Station Road West Ash Vale Aldershot Hampshire GU12 5XA United Kingdom Tel 44 0 1252 371000 Fax 44 0 1252 371007 Internet address http www merrychef com E mail sales merrychef com or service merrychef com Merrychef and MenuKey are registered Trademarks of Merrychef Ltd
11. Merrychef Mealstream 400 SERIES SERVICE MANUAL Part No 3273311 Issue No 9 For all Mealstream 401 and 403 models for GB amp Europe manufactured from January 2001 CAUTION MICROWAVE EMISSIONS DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY Table of Contents oatety eerte e im tes 3 Product 4 Principles of Operation 5 Installation Instructions 6 7 Error Codes and 8 Main Feat res ee 9 Electronic Controls 10 Manual Controls nine e ate gu 11 Power Output Testing to EN 60335 2 90 12 Power Output Testing 13 Power Transformer 13 High Voltage Capacitor 14 High Voltage Rectifier 14 Magnetron Test deed as 14 Door Interlock Operation 15 Error Light Operation eerte rettet 15 16 Door Mechanism 17 Oven Cavity Components amp Hot Air System 18 Oven Door Assembly
12. vog VEL 33 6 621416 LOF INV3HISTV3MW WVYSVIC SNIHIM SZ vC 2 51918 98209 1 AALNO HOF HOLSISI 1 158 1405 L zzl iz oz s1 HANNI WOLLOS 13979401 ZS SS NOILISOd Date 08 2004 40H0072 Issue 6 4 AAN HANHOASNVAHL ATWH TINA EI aavoa 91907 3NVUSNSN 96 201 HOLIMS dol 9 vie Li vo LNO LND ONLLAOHS ANY 33 dV L HALI IN3IAGTI3 HALVAH on 7554815 5 19315 ANY 5270215 lt AIM dd 5350 MALVAH 33 Mealstream 401Ovens 3273311 Issue 9 30A 5 EE amp 1003 it diagram RMC 1003 ircui C 91815 pios eseug lend 2 ejBurs WOE AX 665 1846 LOF NVAYLS IVAW INVHOVIO DNIHIM Date 05 2007 o o 3 o e e o I SE LU MI W
13. 1 Isolate the oven from the mains supply 2 Remove the Logic Assembly from the Control Panel Housing 3 Unplug the membrane tail from the Logic PCB Assy 4 Using a D M M check for continuity between the correct terminals when the pads are pressed 5 When the panel has been tested re assemble and re test the control housing Mealstream 401 3273311 Issue 9 Page 29 Part number identification chart 1 e feme wen DIE EE EEN DIE N EN N w mummenroor Fue s mor ooorseanem woor If replacing a Sanyo Magnetron with a Panasonic Magnetron the HV capacitors need to be changed Mealstream 401Ovens 3273311 Issue 9 Page 30 fer e 65 SWTCHBRACKET RMC7101X01 Am NOT RMC1003 XX52 67 M3 X 25 PAN HEAD PAN HEAD 3123093 e a EIE EIEN N m possen 5 MBSCREW 101 101825 73 220V HEATING ELEMENT 40H0077 74 TEMPERATURE SENSOR SENSOR 508123 Part number identification chart 2 Cw uses EEEN 8 1 3070456 SA TRANSFORMER TOP BRACKET 89 HVLEADASSEMBLY LEAD ASSEMBLY ENT 208 240V 50Hz 90 Transformer 208 240 60Hz 208 240V 60Hz EN TRANSFORMER BOTTOM BRACKET 92 CAPACITORBAND BAND 3070997 EN
14. 5 XE5 XX5 11H0067 11C0066 Menukey XX5 Locare 11H0073 11C0066 95 Membrane Assy See Table 103 Relay Assy EE 11C0286 97 On Off Switch 3070503 103 Relay Assy _ 5 11H0077 98 Logic Assy See Table 103 Relay Assembly Starbucks 11H0201 99 Support Shield 40 0075 107 PCB Stand off 3127010 100 M3 x 5 Screw 3123106 108 15 Way Ribbon Connector 1120298 101 4 x 3 8 Screw 3123112 109 Single 0 25 Blade Tag 309610 102 470R 50W Resistor 3020283 110 Nylon Support 3120206 131 Menukey Assembly 10C0148 Mealstream 401 3273311 Issue 9 Page 27 Manual control panel assembly 96 97 104 105A 106 121 122 123 124A 124B 124B 124C 124C 124D 124E 124E 125 126 127 PCB Retainer LH On Off Switch PCB Retainer RH Side Trim RH M5 Flat Washer PCB Assembly Timer Amber Neon Control Knob Black Control Knob Skirt Red Control Knob Skirt Blue Control Knob Cap Red Control Knob Cap Blue Control Knob Shaft Adaptor Control Knob Assy Black Red Control Knob Assy Blue Pushbutton Start Red Neon Potentiometer 40H0083 3070503 40H0084 MC31212 3125004 11H0027 3070991 316031 313020 313160 3121216 313220 3121217 313030 11C0173 11C0406 3170349 316030 40 0892 Mealstream 401 3273311 Issue 9 Control Board not shown for clarity Page 28 Membrane panel circuit You will need A Digital Multi meter D M M
15. Mealstream 401Ovens 3273311 Issue 9 Page 2 SAFETY CODE This manual is designed to assist engineers who have been on a recognised product familiarisation and tra ining course run by Merrychef Limited It has been prepared to offer technical guidance for the Merrychef Mealstream 400 range of Combination Microwave Ovens Please remember that it is wiser not to attempt a service task if you are unsure of being able to complete it competently quickly and above all safely To avoid injury to yourself and to protect the appliance from possible damage please follow this Safety Code when servicing these ovens Before Note Before attempting to repair the oven check it for microwave leakage Check that the oven is not emitting microwaves even when supposedly not in operation Check that the oven is not operating continuously whether the display indicates cooking or not Always discharge the HT capacitors before working on the oven using a suitably insulated 10 MO Resistor removing the rear cover from the oven ensure you do the following Switch off the mains supply and remove the plug from the wall socket or If the oven is hard wired ensure that the power is turned off at the isolator switch the On Off switch on the oven is not adequate protection against electric shock as it does not isolate all of the internal wiring from the Electrical Supply Upon completion of a service on a Mealstream 401 403 oven or
16. Starbucks 003 XX5 Starbucks 11 0285 1C0285 OMM EES XX5 _ TEE Menukey RMC i008 5 003 5 Locare 1160066 1C0066 Page 31 __ 30 it diagram RMC 1003 ircui C HulyoUMS 1 eseug 5 WOE AX SalHds LOF WV3 LS TV3lW SNIHIM BNO HOLIMS 89 9 SNIVA ole E 2 2 MENNIWOLLOG 149740 H 027 uf 1G 55 40161634 1915 1405 ALIAWO bello MODE 8 el lez 5 e lee le YSWYOISNVYL AVM 39vLT0A 1408 MOT 4400HLL CO 914 ZNOO lat m br p e L 21901 96 SNVSSIASIA HOLIMS Hoog dol 99 ANIT ONILHOHS Fi MOSNag NOSISNEVIA Date 05 2007 40H0233 Issue 9 qu 3513 Zn MALYZH n 551845 1334 ONY STPOZIE SISN LINDYID MALYAH 17 Page 32 Mealstream 401 3273311 Issue 9 RMC 1003 5EE amp RMC 1003 XE rcuit d C
17. 0 minutes each Programmed Mealstream 401Ovens 3273311 Issue 9 Page 4 Principles of operation seuig Buijooo 40 pasn jeued uono seunsue ejqejuun uoneuBem ejqea Ajddns op AO00 t Arddns 94 SUBAUOD JOULIOFSUEI 941 ME eu youm ABjeue AQ00 F ey sueAuoo 941 Aq uye ey JO e ui pue ayeq 35201 seltes OHLON 94 UI pesn pue peoJ0 JOY epio4d pue uorjoeAuoo eur jo sejdiouug Page 5 Mealstream 401 3273311 Issue 9 Installation instructions Positioning the Oven In order to maintain adequate ventilation for air intake and exhaust and to allow access for cleaning the air filters you must allow a minimum of 50mm clearance at the sides and rear of the oven and at least 150mm above Air intake temperature should not exceed 35 Excessive temperature will lead to reduced operating duty cycle or premature ageing of internal components 150mm Clearance for Air Filter at rear of oven Qe lt lt OO QI sels OOOO 6 98885
18. 11 0025 3021230 RMCTMS 5 E HEC MM BRACKET EERE M TRANSFORMER SUPPORT BRACKET 95 MEMBRANEASSEMBLY ASSEMBLY SEETABLE TABLE c o ose ever surrorrsnet mar Transformer Replacement see Appendix 3 Mealstream 401Ovens 3273311 Issue 9 80MM AXIAL FAN 310010 PCB ASSEMBLY 11H0027 TIMER 3020991 316031 CONTROL KNOB BLACK 313020 CONTROL KNOB SKIRT RED 313160 CONTROL KNOB SKIRT BLUE 3171216 CONTROL KNOB CAP RED 313220 CONTROL KNOB BLUE 3121217 CONTROL SHAFT ADAPTER CONTROL KNOB ASSY BLACK RED CONTROL KNOB ASSY BLUE 313030 11C0173 11C0406 3120349 PUSHBUTTON START NEON RED 316030 POTENTIOMETER 40C0892 COOLING FAN 220 240V 50Hz 3071128 COOLING FAN 220V 60Hz 3071190 TURNTABLE MOTOR RMC5055EX DIODE BOARD 11H0058 MENUKEY ASSEMBLY 10C0148 HEATER RELAY 3070986 INLET DUCT 40H0176 CATALYTIC CONVERTER 3171245 CAT COVER 40H0221 VENT PLATE 40H0236 THUMB NUT Model Membrane Assembly E RMC1003 EES XX5_ 5 XE5 XX5 11Ho060 3124031 EE EINE 003 XX5 Starbucks PF 1H0024 EET ak EES XX5 _ ELM Menukey 95 RMC1003 _ Locare 11H0073 RMC1003 EES 5 Haari 11 0285 98 RMC1003_XX5
19. 193X01 3071171 3070088 7101 01 141 3123093 3123118 Mealstream 401 5 3273311 Issue 9 Page 20 Magnetron and door interlock components Model RMC1003 XX5 Model RMC1003 XX52 If replacing a Sanyo Magnetron with a Panasonic Magnetron the HV capacitors need to be changed XX5 models 0 88 to 0 75yF 3071250 54 Door Switch Bracket 40H0023 64 Magnetron Cut out 3070088 55 Primary Microswitch 3070240 65 Switch Bracket RMC7101X01 56 Low Voltage Microswitch 3020240 67 M3 x 25 Pan Head Pozi 3123093 57 Secondary Microswitch 3070240 68 30 Head 3123118 58 Monitor Microswitch 3020240 128 Cooling Fan 230V 50Hz 3071128 59 Microswitch Insulator 3120115 128 Cooling Fan 230V 60Hz 3071190 60 Outlet Duct MC3037 129 Turntable Motor RMC5055EX 61 Foam 3120042 133 Inlet Duct 40H0176 63 Magnetron 3071171 Mealstream 401 3273311 Issue 9 Page 21 Major electrical components JEN my 64 69 70 71 72 73 73 Magnetron Overheat Switch Cavity Overheat Switch Bridge Rectifier EE only No 8 Screw M5 Screw Heating Element 220V Heating Element 240V 3070088 3071031 341520 3123107 101825 40H0077 40H0009 74 75 117 Temperature Sensor HV Diode Assem
20. 6759E 12 Lower Trim MC3122 5 Exhaust Gallery RMC73372 96 Retainer LH 40H0083 6 Rear Panel MC3129 104 PCB Retainer RH 40H0084 7 Air Filter MC3155 105 Side Trim LH MC31211 8 Side Panel R H MC3133 105A Side RH MC31212 Mealstream 401 3273311 Issue 9 Page 16 Door mechanism gt N b 13 Door Stay R H MC3040 14 Hinge Body MC30121X02 15 Hook A RMC66171 16 Hook B RMC66172 17 Door Spring B MC3068X01 18 Hinge Body MC30122X01 19 Door Spring A MC3067 20 Door Stay L H MC3046 21 Microswitch Guide 40H0076 22 Solid Door Assy Black 11H0071 22 Solid Door Assy Silver MC3230X02 Mealstream 401 3273311 Issue 9 Page 17 401 models Oven cavity components and hot air system 23 24 25 26 27 28 29 30 31 32 33 Turntable Disc Baffle Plate Bolt Baffle Plate Fan Fixing Cap Fan Partition Plate Cavity Sealing Glass Oven Body Gearbox Shaft Cooling Fan RMC7340X01 CP30326 MC3018 RCK7617 MC3111 11H0007 RMC7043 MC3013 MC3216 RMC7391X01 RMC7310 34 Motor Bracket RMC7307X01 35 Cushion Rubber RCK8273 36 Motor Fixing Screw CP30310 37 Hot Air Motor MC3110 135 Catalytic Converter 3171245 136 Cover 40H0221 136A Vent Plate 40H0236 137 Thumb nut 3174031
21. BS EN 60335 2 90 This test is given in the BSI test standard for microwave ovens It is reproduced below not so that you can follow it but to show you why it is impractical in normal conditions A simplified procedure which gives a good approximation to the BSI power output is given in Procedure B which follows Note This test can only be carried out on a COLD oven If the oven has been operating even for only a few seconds the power given will be lower than the oven rating This test must also be carried out at a stable voltage the voltage in most kitchens varies considerably even within the period of the test If the oven has been operating go to Procedure B You will need A thermometer capable of reading to 0 1 A cylindrical borosilicate glass container 190 mm diameter with a wall thickness of 3 mm or less A calculator A set of scales capable of reading 1 kg to an accuracy of 1 g A glass or plastic stirrer A jug capable of holding over 1 litre of water Drinkable water which is at a temperature of 10 C 1 C A Variac or similar variable transformer capable of supplying the oven to ensure a stable voltage WARNING The Borosilicate Glass container has thin walls and is therefore fragile lake care not to break it during use Method A cylindrical container of borosilicate glass is used for the test It has a maximum thickness of 3mm an external diameter of approximately 190mm and a he
22. Note When replacing a transformer in a Replacement Transformer Matrix 50Hz oven you will need a new wider bracket 40H0216 for both EE amp Voltage XE products This bracket will fit the 220V existing holes See diagram to right 021233 40H0216 n a Note You will need to fit a new 40H0070 208V bracket to EE amp XE products where EG the original may not have slotted holes 220V 60Hz 3021230 See diagram to right 240V 40H0070 40H0216 Slotted holes Transformer 3071230 shown for clarification Mealstream 401 3223311 Issue 9 Page 44 Manual corrections and modifications Whilst every effort has been made to ensure that the information contained in this manual is accurate and complete if you believe that an error has been made or if you have any suggestions for how the manual could be improved please fill in and return this form A review of any forms returned will be made on a regular basis and the manual will be updated if required Page on which error occurs if applicable Mealstream 400 Series Description of error Suggestion for improvement to manual Please return this form to Service Dept Merrychef Limited Station Road West Ash Vale Aldershot Hampshire GU12 5XA United Kingdom Tel 44 0 1252 371000 Fax 44 0 1252 371007 Internet address http www merrychef com E mail technical support merrychef com Mealstream 401Ovens 3273311 Issue 9 Page 45
23. OLLOS HOLWS 3513 9S j EL gt olo S YINNI WOLLOG 1537901 M 0 7 30151534 28 99 1591 1308 NOILI Od F ALAN 6 vz 698 zz loz le lee al AEA N EL 3514 EI ON 39V L10A OMOIN 1408 MOT Vd n 2200 21901 96 HOLIMS 4000 dol 96 vA MOSN3S ALAYO 10 110 NOMLSNOVIA 229 vo ONILYOHS lt IN3WGT3 H31V3H PEELBLE STINS 13915 SEPOZ IE sasn S3IV3H TIV Page 34 Mealstream 401Ovens 3273311 Issue 9 Circuit diagram 1003 XX5 30A 11 0077 EES WIRING DIAGRAM MEALSTREAM 401 SERIES 5 XX 30A Single amp Dual Phase Solid State Switching 5 ix di RA 40 0234 Issue 3 E a Date 05 2007 Mealstream 401 3273311 Issue 9 Page 35 le Phase XX5 Sing it diagram RMC 1003 ircui C SXX NVAYLSTVAW AVAOVId N 9109 4 027 HOLIMS SNIV on n
24. The oven is now ready to use with the minutes seconds EPS FAIL REDO External Program System ERROR If the key is removed before the download is complete or the process is interrupted the display shows EPS then FAIL then REDO Switch the oven off and begin the MenuKey download again new programs LtLIGULILI To confirm the download is successful Switch off the oven Switch on and the display briefly will show the following 1 The new key code 2 00 00 oven ready to use If the download is not successful the key number will not be displayed and if the program pads are pressed an E3 error will display Mealstream 401 3273311 Issue 9 Page 42 APPENDIX 2 Cleaning Procedure Follow the SAFETY INSTRUCTIONS at the beginning of this manual ALWAYS switch off at the electrical supply and allow oven to cool for at least 20 minutes before cleaning As required remove carousel and wipe out spillages with disposable paper wipes NEVER use steel wool knives or harsh abrasives on any part of the oven As with all electrical appliances it is wise to have the electrical connections inspected periodically Cleaning the air filter oven cavity and door DO NOT SPRAY ANY CLEANING FLUID DIRECTLY INTO THE CATALYTIC CONVERTER VENT HOLES AT THE REAR OF THE OVEN CAVITY THIS WOULD CAUSE PERMANENT DAMAGE TO THE CATALYTIC CONVERTER Mealstream 403 1 Remove trays
25. before reconnecting the appliance to the mains supply for testing check all of the following points Before All internal electrical connections are correct All wiring insulation is correct and is not touching a sharp edge All Earth connections are electrically and mechanically secure All four door safety interlocks are secure and mechanically sound The door operation is smooth and the arms run freely in the slots The door activates all four of the door interlock switches in the correct order All fuse holder safety covers are correctly fitted The temperature sensor is correctly connected to the Power PCB finishing the service call recheck the following points All of the electronics are functioning correctly and all of the touch pads are working The turntable is rotating correctly The power output of the oven is correct see pages 12 amp 13 Microwave emission is below permissible limit 5 mW cm see BS EN 60335 2 90 Oven has correct 50mm air gap all round and 150mm above Air flow should not be restricted Mealstream 401Ovens 3273311 Issue 9 Page 3 Product specifications Mealstream 401 amp 403 models ELECTRONIC CONTROLS EC401 amp EC403 models Model RMC1003 Voltage Frequency Current Controls Catalytic converter RMC100345XE52MK 230 240V 50Hz 30A Series 5 Controls Twin Phase MenuKey Model Voltage Freq
26. bly Axial Fan 80mm 50E123 11H0010 310010 Mealstream 401Ovens 3273311 Issue 9 Page 22 Input wiring filters and fuses Model RMC1003 5 XD Model RMC1003 5 CD2 Green Yellow Green Yellow 112 1128 115 111 Mains Input Block 112 Cable Gland 112A Cable Gland Nut 113 Input Cable Assembly 115 XE5 Input Cable Assembly 116 Strain Relief Grommet 3120328 3121070 3121082 3120220 302030 3121036 77 Microwave Mains Filter 16A 78 Heater Mains Filter 16A 79 Fuse Cover 80 Fuse 10A HRC 81 Holder 1 82 Fuse 13A 3070997 3020997 2021080 3070217 3020231 3020456 Mealstream 401 3273311 Issue 9 Brown Page 23 Input wiring details Model RMC1003 5 XX52 Green Yellow Green Yellow Blue 111 112 11289 115 111 Mains Input Block 3170328 112 Cable Gland 3121070 112A Cable Nut 3121082 113 Input Cable Assembly 3120220 XX5 Input Cable Assembly 116 Strain Relief Grommet 3121036 77 Microwave Mains Filter 16A 3020997 78 Heater Mains Filter 16A 3020997 80 Fuse 10A HRC 3070217 81 Fuse Holder 1 3070231 82 Fuse 13A 3070456
27. e the oven before testing 2 Ensure that the High Voltage Capacitor is discharged before commencing work 3 Remove all connections from the Power Transformer 4 Using a D M M check the continuity of the windings Results should be as follows Mains winding between tags Approx 1 3 0 b High Voltage winding Approx 50 100 C Filament winding Less than 1 Q between terminals 5 Using a Megger test the insulation resistance between Primary winding and chassis Pass if over 10 MO CHASSIS Filament winding and chassis Pass if over 10 MO One end of the High Voltage winding is connected to the chassis so this is not tested Mealstream 401Ovens 3273311 Issue 9 Page 13 Procedure D High Voltage Capacitor Test You will need Digital Multi meter D M M A Megger or similar resistance meter using 500V d c WARNING High voltages and large currents are present at the High Voltage Capacitor It is very dangerous to work near this part when the oven is on NEVER make any voltage measurements at the High Voltage circuits including the magnetron filament WARNING Even when the oven is not cooking the High Voltage Capacitor has High Voltages present because of the Soft Start circuit Isolate the oven before testing 1 Isolate the oven from the mains supply 2 Ensure that the High Voltage Capacitor is discharged before commencing work 3 Remove all connections from the High Voltage Capacitor 4 Us
28. ight of approximately 90mm The mass of the container is determined At the start of the test the oven and the empty container are at ambient temperature Potable water having an initial temperature of 10 C 1 C is used for the test The temperature of the water is measured immediately before it is poured into the container A quantity of 1000g 5g of water is added to the container and its actual mass obtained The container is then immediately placed in the middle of the oven on the turntable The appliance is supplied at rated voltage and operated at the maximum power setting The time for the water temperature to attain 20 C 2 C is measured The oven is then switched off and the final water temperature is measured within 60seconds NOTES 1 The water is stirred before its temperature is measured 2 Stirring and measuring devices are to have a low heat capacity The microwave power output is calculated from the formula 4 187 Mw T2 T1 0 55 Mc 2 where P isthe microwave power output in watts My is the mass of the water in grams Mc is the mass of the container in grams To is the ambient temperature in T4 isthe initial temperature of the water in is the final temperature of the water C t the heating time in seconds excluding the magnetron filament heat up time Mealstream 401 3273311 Issue 9 Page 12 Procedure Simplified P
29. ing a D M M check for continuity between the terminals amp Between Terminals Between Terminals and Case 5 Using a Megger test the insulation resistance between the terminals and the case Between Terminals and Case Pass if over 100 Procedure E High Voltage Rectifier Test You will need A Megger or similar resistance meter using 500V d c WARNING High voltages and large currents are present at the High Voltage Rectifier It is very dangerous to work near this part when the oven is on NEVER make any voltage measurements at the High Voltage circuits including the magnetron filament WARNING Even when the oven is not cooking the High Voltage Rectifier has High Voltages present because of the Soft Start circuit Isolate the oven before testing 1 Isolate the oven from the mains supply 2 Ensure that the High Voltage Capacitor is discharged before commencing work 3 Remove all connections from the High Voltage Rectifier 4 Using the Megger test for continuity in both directions Compare results with the table Procedure F Magnetron Test You will need A Megger or similar resistance meter using 500V d c A Magnetron can be tested for an open filament or a short circuit by carrying out a continuity check 1 Isolate the oven from the mains supply 2 Ensure that the High Voltage Capacitor is discharged before commencing work 3 Remove all connections from the Magnetron 4 A continuit
30. l Serial Number Electrical Ratings and Manufacturers Tel no DOOR The door consists of a thermally insulated inner section and an additional air gap provided by a twin skinned door front to lower the surface temperature ON OFF SWITCH This is used to turn the oven On or Off IT DOES NOT ISOLATE INTERNAL WIRING FROM THE ELECTRICAL SUPPLY FEET These feet are fitted to ensure adequate airflow under the oven They must not be removed ELECTRICAL SUPPLY LEAD AIR FILTER Main intake for cooling air for internal components Must be clear of obstructions MenuKey Page 9 Electronic controls Mealstream EC401 403 a Stage LED s b Service Indicator Air Filter Block Indicator d Operator error indicator e Program Display f Temperature Set Pads g Time Program Number Pads h Cancel Callback Pad i Program Pad j Convection Pad k Microwave power Pads On Off switch socket Starbucks model Mealstream 401 3273311 Issue 9 Page 10 Manual controls Mealstream RD401 a Temperature Amber Neon b Temperature Control c Microwave Power Control d Timer e Start Pushbutton f Cook cycle Red Neon 9 Amber Neon h On Off switch Mealstream 401 3273311 Issue 9 Page 11 Procedure Power Output Test In accordance with
31. me 4 2 Invalid time has been set Set a valid time 3 Invalid program has been set Use call back to check program i 4 Number pad failure Menukey no key downloaded Membrane key short circuit 5 Memory Failure running a Re Program Pad Program if fault repeats replace Logic PCB 1 Oven is not at correct Allow oven to reach correct M t temperature to start program Programmed temperature Operator Error 1 Magnetron overheating Check that magnetron cooling fan is 1 working correctly Check air filters ES Check location and air inlet temperature Note this will lead to condition shown below 1 Magnetron has overheated Check that magnetron cooling fan and but has now recovered turntable are working correctly 2 Internal diagnostic fault Check installation air inlet temperature and air filters 1 control area is Check air filters overheating Check axial fan Check installation for hot air intake 5 MenuKey removed before the download is complete or the process has been interrupted Switch oven off and begin the MenuKey download again Mealstream 401 3273311 Issue 9 Page 8 Main features ul rear view of Oven a STEAM OUTLET Allows steam and excess pressure to escape from the oven cavity It must be kept clear b AIR OUTLET Warm air is vented here It must be kept clear c TRAY HANDLE RESTS There is one on each side of the
32. oven for convenient storage of the tray handle d BAFFLE PLATE Forms the inside rear of the oven and covers the hot air circulation fan Removable for cleaning by unscrewing the four wing nuts which hold it in place This must be cleaned on a regular basis and kept free of debris BAFFLE PLATE amp CATALYTIC CONVERTOR 403 model only Allows extraction free cooking Should be removed regularly for cleaning Do not spray put caustic cleaner directly into the catalytic converter as this will cause permanent damage e RUNNERS These mounted on each side of the oven cavity to support the rectangular racks or oven trays and are for use in Convection mode only HOT AIR FAN Situated behind the baffle plate and circulates the hot air through the baffle plate over the heating element and around the edge of the baffle plate back into the cavity g OVEN CAVITY The oven cavity is mainly constructed form vitreous enamelled steel panels It must be kept clean Mealstream 401Ovens 3273311 Issue 9 5 5 TURNTABLE TRAY The vitreous enamelled turntable tray fits onto the turntable disc in the bottom of the oven cavity and rotates during cooking to ensure an even distribution of microwave energy AIR INLETS Additional air inlets are situated along the lower edge of the left hand side panel and must not be obstructed RATING PLATE The rating plate is situated on the rear of the oven and states the Mode
33. ower Output Test You will need A thermometer capable of reading to 0 1 A Polypropylene tray approximately 200 mm x 200 mm A measuring jug A calculator Water which is at a temperature of 10 C 2 1 Measure 1 litre of cold water into the tray using the measuring jug 2 Measure the water temperature and record it as T s 3 Place the tray on the turntable in the oven and close the door 4 Turn the oven on 5 Set the timer to 1 02 For Manual controls use a stopwatch set to 1 minute 2 seconds 6 Press the 100 power pad 7 When the oven bleeps open the door and remove the tray 8 Stir the water thoroughly and measure its temperature Record this as T e Calculation 1 T s 2 Power 70 x T r Power is in Watts The power given by the above test should be within 10 of the rated power Procedure C Power Transformer Test You will need A Digital Multi meter D M M A Megger or similar resistance meter using 500V d c 1 Isolate the oven from the mains supply WARNING High voltages and large currents are present at the secondary winding and filament winding of the Power Transformer It is very dangerous to work near this part when the oven is on NEVER make any voltage measurements at the High Voltage circuits including the magnetron filament WARNING Even when the oven is not cooking the Power Transformer has High Voltages present because of the Soft Start circuit Isolat
34. racks turntable and turntable disc from the oven cavity and air filter on the rear panel Clean using non caustic oven cleaner Wash off using a clean cloth and plenty of clean warm water Dry using a fresh clean cloth Mealstream 403 Model only To remove the catalytic converter at the rear of the cavity undo the three thumb nuts to release the cover plate and carefully lift out Wash the catalytic converter in CLEAN HOT WATER only do not use cleaning products which could cause permanent damage to the filter Leave to dry Clean the cover plate in non caustic oven cleaner and dry using a fresh clean cloth 2 Remove food particles from between the inside edge of the door and the front of the oven floor using a clean dry brush Location A Apply non caustic oven cleaner to interior surfaces except door seals and leave for the recommended time Wash off using a clean cloth and plenty of clean warm water Dry using a fresh clean cloth 3 Wipe hinges with a clean damp cloth DO NOT apply lubricating oil to hinges 4 Wipe door seals carefully with a clean damp cloth Examine for signs of wear or damage 5 Mealstream 403 Model only Replace the Catalytic Converter and cover plate ensuring the face of the converter with the spacing edge is facing If the door seals are damaged the oven must be repaired by an approved Service Engineer outwards to allow air to pass efficiently through the filter Tighten up the three
35. rcuit is not overloaded BLUE BROWN Where an approved and fitted moulded plug is NEUTRAL supplied we strongly recommend that this plug is never removed However certain establishments may require a Diagram 1 different plug to be fitted In this case the wiring instructions shown should be observed Models RMC1003 XE5 RMC1003 XD RMC1003 5 When supplied single phase models are fitted with a Blue 32Amp Plug approved to BS4343 Wiring cable colours as shown in Diagram 1 The Circuit Breaker should be rated at 45A TypeC TWIN PHASE YELLOW viue Models RMC1003 XE52 RMC1003 XX52 TO EARTH L 1 The Mealstream 401 oven Twin Phase models L should be connected as shown in Diagram 2 2 The Circuit Breaker should be rated at 20A per phase BLUETO BLACK NEUTRAL TO LIVE No2 Simplified loading Diagram Diagram 2 N MICROWAVE CONVECTION HEATER Not Used Mealstream 401Ovens 3273311 Issue 9 Page 7 Error codes and diagnostics The control panel will identify some of the most common problems by flashing an error message code in the time display window Error Message Possible Cause Service Door not fully shut Close door fully 2 Possible electrical fault Check Microswitch Door Circuit 1 Check Microswitch Connection to PCB Check Ribbon Cable Check Relay PCB amp Logic PCB 1 time has been set Set a ti
36. ssion if all three of the other switches have failed Note If operation of the Monitor switch has caused the Microwave Fuse to blow the Primary and Monitor microswitches must be changed as they may have been damaged by the high short circuit currents involved Error Light Operation The Air Filter Blocked light and Service light are triggered by the internal circuitry If the magnetron overheats the error code 7 is displayed on the front panel and both the Air Filter Blocked and the Service indicators will light Once the magnetron has cooled sufficiently to allow the oven to restart the Service light will remain illuminated until the oven is turned off This fault may have been triggered by one of the following causes Air inlet on rear of machine being obstructed High air inlet temperature Slow running cooling fan jammed turntable or broken gearbox cooling fan also drives turntable Faulty magnetron overheat stat or associated wiring Note that the customer may not have noticed that the oven displayed E 7 and so the reported fault may be misleading Mealstream 401Ovens 3273311 Issue 9 Page 15 Principal components casework 1 Side Panel MC3134 9 Handle Hanger RCK6319 2 Ferrite RMC6773 10 Rubber Foot RMC6104 3 Upper Trim MC3120X01 11 Front Lower Panel MC3047 4 Top Plate RMC
37. thumb nuts Cleaning the control panel and exterior surfaces Wipe down regularly with a damp cloth Hints and Tips for stubborn stains in the oven cavity Switch on oven with microwave power only without heat Set microwave power to 100 Set timer to 30 minutes and press start button At end of steam cycle wipe out cavity with a clean cloth Mealstream 401 3273311 Issue 9 Place a container of water 1 5 litres into the centre of the oven cavity Faults arising from neglect or misuse including use without clean filters in place are not covered by the guarantee Service visits as a result of such faults will be chargeable Merrychef recommends the use of approved Merrychef Oven Cleaner and Merrychef Oven Protector DO NOT USE THE OVEN WITHOUT A CLEAN AIR FILTER IN POSITION rear of oven cavity Thumb Nut x3 Page 43 APPENDIX 3 Transformer Replacement Procedure Should you need to change a transformer to any Mealstream 401 EE or XE product you should use the new 3071233 or 3021230 multi tap transformers see matrix below Note The capacitor values remain the same when using the new 3071233 or 3071230 transformer Parts required 1 Pt No 3021233 Transformer 50Hz Multi tap 220V 240V 2 Pt No 3021230 Transformer 60Hz Multi tap 208V 240V 3 Pt No 40 0216 50Hz multi tap transformer bracket 4 Pt No 40H0070 Standard bracket with slotted holes
38. uency Current Control Supply MenuKey Catalytic prefix Type Phase converter RMC1003 2 220 230V 5 50 Hz EE 13A 5 2 MK C 4 230 240V 6 60 Hz XE 30A Series 5 Twin si controls Phase 30A A Catalytic converter is fitted to Mealstream 403 models only MANUAL CONTROLS RD401 models Model N RMC1003 Voltage Frequency Current Model prefix Voltage Frequency Current RMC1003 2 220 230V 5 50Hz CD2 13amp 4 230 240V 6 60 Hz XD2 30amp Power See RATING PLATE on rear of oven Requirements Power Output Microwave 100 700W XE IEC 705 Convection 3000W XX5 Combination 700W 1500W 700W 3000W 1000W 3000W XX5 External Height 530 mm Plus 150 mm minimum clearance above Dimensions Width 550 mm Plus 50 mm minimum clearance each side Depth 575 mm Plus 50 mm clearance behind Internal Height 315 mm Dimensions Width 330 mm Depth 330 mm Turntable 300 mm Diameter Capacity 34 3 litres Weight Nett All models except XX5 45kg 5 55kg Gross packed All models except XX5 58kg 5 68kg Construction Cavity Vitreous Enamel Coated Steel Casework 304 Stainless Steel Anodised Aluminium Extrusions Settings Microwave 100 75 50 25 Convection only Temperature Off 175 C 200 C 225 C 250 C 275 C Timer Up to 30 minutes Up to 3 cooking stages of up to 3
39. y check across the Filament terminals should be 1ohm or less 5 A continuity check between each filament terminal and the metal outer should read open Mealstream 401 3273311 Issue 9 Page 14 Door interlock operation The door on the oven is monitored by four microswitches Three of these are used in the conventional Primary Secondary and Monitor switch arrangement shown below while the fourth is a low voltage switch linked directly to the control circuitry The switches operate as follows Door Interlock Arrangement 56 Top RH 57 Bottom Inner L Top LH 55 Guler aS x Power Out N 1 Primary Interlock 55 Top Left Hand and Low voltage 56 Top Right Hand Switches Operate simultaneously Either will cut off the microwave emissions from the oven when the door is opened the Primary switch by breaking the mains supply circuit to the transformers and the Low Voltage switch by breaking the relay circuit on the Power Relay PCB 2 Monitor 58 Bottom Outer and Secondary Interlock 57 Bottom Inner Switches Operate simultaneously The Monitor switch will produce a short circuit across the mains supply if the Primary interlock switch is faulty thus blowing the microwave fuse and rendering the oven inoperative The Secondary interlock switch will cut off the microwave emi
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