32Z3522 402S Service Manual USA issue 6.pub
Contents
1. Version 3 0 Version 2 0 Merrychef O 2 S US Models including WAWA SERVICE amp PARTS MANUAL This manual covers US models manufactured from ISSUE 6 Version 2 0 Serial No 000745 001199 Version 3 0 Serial No 001200 onwards 18 03 2008 CAUTION MICROWAVE EMISSIONS DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY TABLE OF CONTENTS Microwave safety precautions 3 Sale Seo 4 Product 5 Installation instructions 6 IVAN Teatre hss See ose 7 9 Principal components 10 Principal components LHS 11 Principal components Top 12 Principal components Back 13 Principal components Power Supply 14 Principal components Cavity 15 Principal components External Panels 16 Principal components Control Panel 172. _ lt lt 1 lt 1 lt lt lt lt NO N 2 gt O A LI gt 402s Ovens Pt No 3243522 Issue 6 41 APPENDIX 4 Recommended spares lists USA CONT ZCNMNCTCENNDIEJCUE IEEE Dvos28 HEATER ELT HEATER ELT 208V 650W WATLOW 650W WATLOW 3 __ pvos2 _ stiRRERcoveR cerawic amp 2 2 2 s 2 2 bus poors _ 8 s LL 3 bus pooncexevi 3 ew Sw poonasewayvi o 3 san poose 77 frfa f Pe MEAN DOOR HINGE ASSEMBLY RA fafs ee gt SA202 DOOR HINGE ASSEMBLY RH bacs 4025 GREASE FILTER UPGRADE 1 CERAMIC COVER UBGRADE KT 1 ca ws mowrrRSws amp amp pum posmen azsa aoas stop upcrapeKT amp pue emen Ew Sacs STRRERMOTOR ASSY PINNED 1 Prisa Ro INJO 2 gt gt gt NO NO NM NM oO x SA311 IMPELLER HOT AIR MOTOR prove pemeereswwwenwin 1 pos 3 pos 3 _ 3 ig poo m 1 _ 72 o4 a
3. Air intake temperature should not exceed 110 F 45 C excessive temperature will lead to reduced operating duty cycle or premature ageing of internal components Failure to comply with these conditions will invalidate the warranty NEVER Install an oven above fryers grills griddles or any other major heat source ALWAYS Place containers in the cavity carefully impact damage may chip the vitreous enamel coating on the runners and Note baffle plate The minimum recommended clearance required for air flow Mins 402s Ovens Pt No 3243522 Issue 6 6 MAIN FEATURES On Off SWITCH This is used to turn the oven On or Off IT DOES NOT ISOLATE INTERNAL WIRING FROM THE MAINS SUPPLY MenuKey The MenuKey System automatically changes all the cooking programs with an electronic key and allows program names to be identified OVEN CAVITY The oven cavity is mainly constructed from stainless steel panels It must be kept clean GREASE FILTER The grease filter must be cleaned on a regular basis and kept free of debris RACK The cooking rack should be removed daily and cleaned HOT AIR FAN Situated behind the grease filter and circulates the hot air through the cavity RATING PLATE The rating plate is situated on the rear of the oven and states the Model Serial Number Electrical Ratings
4. pos _ pos 3 ae DUNS _ 6 m Lo uw _ 6 30 pi z 6 3 ps 3 o2 2 27 2 o2 2 o6 3 gt 2 E 2102 2 JIV gt gt gt gt gt gt gt 65 amp iNeo 402s Ovens Pt No 3243522 Issue 6 42 APPENDIX 5 LOGIC PCB Connection Points and key features Spare input not used Display Connecter Temp Calibration Relay PCB 15 way Connecter Door Switch IP Door switch _ oo Indicator EET om ON when door closed Remote data point MenuKey Sockect Connector Program Motor speed D7 Power LED memory storage controller Indicates Logic PCB May be is powered exchanged See Troubleshooting with New PCB if PCB replaced Membrane panel Guide connector 402s Ovens Pt No 3243522 Issue 6 43 APPENDIX 5 Relay PCB Connection Points and key features P d d 1 D15 Cavity 3 23 3 e p D16 Magnetron soft start Input Magentron D19 Heater ON Overheat sensor Inputs D20 LED ON when power is on OFF when Microwave is operated gt a 2 4 T m ae oO M Connector To r 2 O I O 00 1x 0 P 4 JPS 07 3 U1 Ambient air temperature ii D sensor d d Art S bili aww Display N Fuse Fuse DA ipa Not Used AC input from Aux Transfo
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6. Check 15 Way Ribbon Cable between Logic and Relay PCB Using spare display connect to Logic PCB Still Have a Problem Spare Display Still Dead works Replace Check Connection Output Display at Aux Transformer Check Power supply to Relay PCB Check Fuse on Relay PCB Still Have a Problem Replace Logic PCB 402s Ovens Pt No 3243522 Issue 6 31 Cold Food Check Convection Temperature control NO OK Possible Temperature Sensor Fault Check Current using clip on current Assuming sensor Ok then make sure meter through F7 and F8 When door Light on logic PCB is on when running Microwave only You will door closed If this is working then need to reset the pre heat replace Logic PCB temperature to 0 and enable manual control via the profile setting Make Also check that convection motor is sure that there is a water load in operational the cavity Less than More than 5 Amps 5 Amps Check that the stirrer is rotating Yes No Carry out Microwave Output Test Replace stirrer motor and retest LOW OK Check Microwave Generating system Contact Merrychef Service Department for Further Transformer assistance Magnetron Capacitor Diode 402s Ovens Pt No 3243522 Issue 6 32 Cavity Sensor Error Report to Are there any Signs of Management and Cavity Fire Make Investigation Replace Sensor Retest and calibrate Oven Check Temperature Sensor Resistance OK
7. fire in oven cavity Note In service operations when PREHEAT is set to O F this message can appear when the oven is operated 402s Ovens Pt No 3243522 Issue 6 8 MAIN FEATURES Electronic control panel Version 3 0 COOL DOWN MAIN DISPLAY Be MenuKey FUNCTION PADS MenuKey 2 The MenuKey System automatically changes all the cooking programs with an electronic key and allows program names to be identified CANCEL PAD Cancels all timed cooking cycles pre programmed operations and stops the microwave energy It does not alter the oven temperature If the oven is hot food will continue to cook and should be removed from the oven immediately This pad will also cancel any incorrect operations It will not erase programs FUNCTION PADS FUNCTION CANCEL PADS PAD DISPLAY PANEL Shows the principal functions of the oven When cooking the time remaining counts down Also displays error messages and oven temperature When storing and recalling a program the display indicates the program number and details FUNCTION PADS The funct
8. FAIS IV AI a eaten waa f 18 19 Procedure for Microwave Emission test 20 21 Procedure for Power output measurement 22 Procedures for Principal Component tests 23 24 Procedure for door interlock adjustment 25 26 Hot Air Motor and controller 2 28 Wining Diagrams Duke dowd Deoa EE 29 Trouble Shooting 30 34 Appendix 1 Temperature 35 Appendix 2 MenuKey Procedures 36 37 Appendix 3 Cleaning Procedure 38 40 Appendix 4 Recommended Spares List 41 42 Appendix 5 PCB connection Points 43 44 Appendix 6 Engineering Test Settings 45 Appendix 7 Firmware revision 46 51 Merrychef USA 1111 North Hadley RD Fort Wayne IN 46804 Phone 800 678 9511 Fax 800 285 9511 e mail info merrychefusa com 402s Ovens Pt No 3243522 Issue 6 2 MICROWAVE SAFETY PRECAUTIONS CAUTION WARNING TO SERVICE TECHNICIANS PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY a Do not operate or al
9. immediately press Profile to edit the oven operating profile OVEN MODE 3 Press Change to set PROGRAM MANUAL OVEN MODE to PROGRAM MANUAL Then press Next five times to return to the OVEN COLD standby screen To use Manual Mode from the CATEGORIES To use MANUAL MODE standby screen press the lower centre right pad from the OVEN COLD PRESS PREHEAT To display the Manual mode screen standby screen press the PREHEAT COOL DOWN pad on the control panel and then press Manual CAT 001 CATEGORIES CAT 005 CAT 002 CAT 006 CAT 003 V CAT 007 CAT 004 Y UNL008 READY TO COOK AT 000 F PREHEAT COOL Run Prog DOWN 402s Ovens Pt No 32 3522 Issue 6 45 APPENDIX 7 Firmware revision guide As a result of on going changes upgrades to the 402s Oven this Appendix has been produced stating the following 1 0 An overview of the control system for a 402s 2 0 How to check your Firmware version 3 0 How to check your hardware fitted 4 0 CODEKEY firmware upgrade 5 0 MenuKey2 download CODEKEY Reference See Table 1 for abbreviations description Version 3 Part No 31 7066 3 0LD 402s Large Display UK EU Part No 31 7068 3 0LD 402s Large Display French Part No 31 7071 4 310 402s Large Display UK EU Part No 31 7072 4 310 402s Large Display French Part No 3127073 4 410 402s Large Display US EU FO SSR EMD NSS NPM NEP For QSR restaurants FO EMD FO EMD FO S
10. No 3243522 Issue 6 50 4 3 To confirm a successful download check that the Software Version on the oven and the CODEKEY fob Label are the same OVEN INFORMATION Oven On Time 00028 Hours Magnetron On Time 00000 Hours Door Operations 00049 Software Version 4 3LD MenuKey Code 002 MenuKey Checksum F076 EXIT gt gt Software Version Software 4 3LD CODEKEY Date 00 00 07 Fob cs 0x9C71 Label merrychef 4 4 Press exit and remove and retain the CODEKEY 5 0 MenuKey2 download Procedure Before commencing a MenuKey download ensure the oven is switched OFF 1 Insert the appropriate MenuKey into the control panel socket 2 Switch the Oven ON DO NOT REMOVE the Menukey as this will corrupt the data on the key 3 The display will show the following MenuKey Detected Copying Programs from Verifying Programs MenuKey Copied Please Wait MenuKey to Oven Copied successfully Successfully The display will show the start sequence the Oven will begin heating up Remove the MENUKEY 402s Ovens Pt No 3273522 Issue 6 51
11. Re Start Oven Activate Pre heat Yes LED is on Is Led D19 on relay PCB ON Check Heater Elements Replace if necessary Check door Switch LED is on LED on logic PCB Is the temperature display saying too hot Check the Door Interlock Switch Check The interconnecting lead to the logic PCB Cavity Sensor error is caused by one of the Assume the Cavity is following not too hot then 1 The cavity did not heat by 180 F in the 10 Minutes Replace Sensor 2 The cavity exceeded the set point when cooking by more than 72 F whilst cooking which indicates that the food load was on fire 402s Ovens Pt No 3243522 Issue 6 33 Magnetron Overheat issues Remove and Clean Air Filters If Dirty Advise operating staff of the need for this to be carried out on regular basis See User Manual Still have a problem Check Location of oven is away from any major heat sources Recommend re location if necessary Location fine and still have a problem Check cooling fan operation Make sure there is Noticeable airflow from air vents at the rear of the oven If Not investigate and replace cooling fan if necessary Fan is fine and still have a problem Magnetron Error reported Ambient Magnetron or Ambient Note Each Magnetron has a thermistor attached to it The control unit will produce an error if the temperature exceeds 235 F The Ambient Air Sens
12. cleaning Use a non abrasive nylon scrub pad sponge to clean all internal sur faces and the inside of the door Remove top impinger plate Undo fasteners To remove grease filter push down and lift out 3 Wash off using a clean cloth and plenty of clean warm water to rinse top sides and back of oven Dry using a fresh clean cloth or paper towel Wipe the outside of the oven with a damp cloth DO NOT use the oven without clean air filters and cavity grease filter in place 40 A 402s Ovens Part N 32 3522 Issue 6 4 Replace clean oven parts Grease Filter Top plate Bottom plate Air filters x2 DO NOT USE TOOLS When replacing impinger plates and the cavity grease filter use firm finger pressure to tighten fasteners DO NOT USE TOOLS APPENDIX 4 Recommended spares lists USA Lom Iu Pe it Kit ens Ovens Ovens Ovens M1H0010 HT HT DIODE ASSY ASSY nr O 1100004 WAmRELAYPCB _________ 1 EA a 1 3 6 3 Moos jwNuKevsocETAY _ 1 E 3 3 pes ifa vr e s ron 1 f ea monz DC VOLTAGE CONNECTOR WAY 3 _ VCKHTDIODEASSEMBLY gt 11Z0298 15 WAY 0 1 RIBBON CABLE ASSY FUSE 1in 10A HRC FUSE HOLDER 1IN 13A GOLD RESISTOR 220R FUSE 1x1 4in 1A HBC MAINS OVERHEAT SAFETY STAT BLOCK TRANSFORMER B0012024 eo a
13. hot box at the rear of the oven cavity The hot air from the hot box passes over catalytic converters and is circulated into the bottom and top of the cavity through the impinger plates It returns through the removable grease filter at the back of the cavity and into the fan Convection motor The convection motor Is a 3 phase AC motor having a maximum speed of 7200 rpm controlled by a motor speed controller The windings are thermally protected and in the event of a thermal fault a trip will operate and shut down the motor speed controller Motor controller fault finding 208V 240V 60Hz Electrical supply into motor controller Three phase connections to motor Speed Controller connections to logic board Step Motor thermal cut out short circuit N Motor rotates freely not seized Motor winding resistances Blue Black 3 Ohms 4 Ohms Black Brown 3 Ohms 4 Ohms Brown Blue 3 Ohms 4 Ohms Black or Brown or Blue to Earth Open circuit 20 Heater Element 208V 650W 680 DV0328 20 Heater Element 240V 650W 880 DV0337 20A Heater Element Collar DV0058 23 Convection Hot Air Motor Assembly SA208 Gasket Set SA332 8x 3124016 M5 Flange nut 402s Ovens Pt No 3243522 Issue 6 27 PRINCIPAL COMPONENTS Hot Air Motor amp Controller 2 Motor Controller Provides an AC 3 phase switched mode drive to the convection motor and is controlled by a 0 10 Volt signal from the logic board This allows the motor t
14. mains supply Ensure that the High Voltage Capacitor is discharged before commencing work 3 Remove all connections from the High Voltage Capacitor 4 Using a D M M check for continuity between the terminals amp compare results with table on next page 402s Ovens Pt No 3273522 Issue 6 23 PROCEDURES FOR PRINCIPAL COMPONENTS TEST 2 High Voltage Capacitor Test continued ensure steps 1 4 on previous page have been completed Between Terminals Pass if approximately 10 MQ Between Terminals and Case Pass if open circuit o Using a Megger test the insulation resistance between the terminals and the case Between Terminals and Case Pass if over 100 MQ 3 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 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 See Safety Code Page 4 1 Isolate the oven from the mains supply 2 Ensure that the High Voltage Capacitor is Open Circuit both ways FAIL discharged before commencing work 3 Remove all connections from the High Voltage Conducts one way
15. microwave with the door open WARNING Before adjusting the microswitch assemblies ensure that the oven has been isolated from the electrical supply Please note the terminals on the microswitches remain live when the oven is switched off so 1 i complete isolation is essential Objective With a 1mm spacer located as shown both switches on both sides should be activated closed position With a 5mm spacer located as shown SW2 and SW3 should be open Method of adjustment By loosening the four screws on each mounting bracket the microswitch assembly can be raised or lowered and thereby the switches can be made to operate at different door positions Procedure 1 Isolate the oven from the Electrical supply 2 Place a 1mm spacer between the cavity face and the door seal as shown 3 Working on the right hand side adjust the bracket so the SW2 just operates 4 Working on the left hand side adjust the bracket so that SW3 just operates 5 Remove the 1mm spacer and then place a omm spacer in the same position Check that SW2 and SW3 are open circuit and not operated 6 Repeat the steps above to ensure the setup is correct 7 Ensure that all the screws are tightened 8 Reconnect the electrical supply 402s Ovens Pt No 3273522 Issue 6 26 PRINCIPAL COMPONENTS Hot Air Motor amp Controller 1 Convection and Fan Speed Control The convection heat is provided by 5 elements located in the
16. only PASS Rectifier Short Circuit both ways FAIL 4 Using the Megger test for continuity in both Conducts one way leaks the other FAIL directions Compare results with the table 4 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 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 See Safety Code Page 4 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 continuity check across the Filament terminals should be 10hm or less 5 A continuity check between each filament terminal and the metal outer should read open 402s Ovens Pt No 3273522 Issue 6 24 PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST 1 The door on the 402s oven is monitored by four microswitches Three are used in the conventional Primary Secondary and Monitor switch arrangement shown below and the fourth sends a
17. signal to the Logic PCB The switches operate as follows Door Interlock Arrangement Switches shown in Door Closed position Monitor switch RHS E LHS el Oo l L1 Primary i switch x x Power Powerln Out 1 Monitor switch The Monitor switch will produce a short circuit across the mains supply when the door is opened if the Primary interlock switch is faulty thus blowing the microwave fuse and rendering the oven inoperative 2 Primary Interlock and Secondary Interlock The Primary switch will cut off the microwave emissions from the oven when the door is opened by breaking the electrical supply circuit to the transformers The Secondary interlock switch will cut off the microwave emission if the Primary switch has 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 Right Side Microswitches RH side Monitor Primary SW 1 SW2 o Left Side Door closed Secondary Logic PCB SW3 SW4 402s Ovens Pt No 3273522 Issue 6 25 PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST 2 It is vital that the microswitches are adjusted to the correct position There are two sets switch assemblies located either side of the oven The interlocks ensure that the oven will not operate
18. 20 C and measure the water temperature Use a thermometer with a 0 0 1 degree gauge 2 Place the beaker in the centre of the cold cavity 3 Version 2 0 Press the Manual Function Pad to enter Manual Mode Manual Mode Version 3 0 Press the lower RH function pad below the display to enter If the manual mode Manual Mode Set Time to 1 minute 3 seconds Power to 100 and Fan to 0 Press the Start pad and wait until the counter reaches zero screen does not appear it must be changed in the 4 Take the beaker out immediately stir the water with a plastic implement OVEN PROFILE see and measure the water temperature Appendix 6 Calculate the temperature rise of water in the beaker The temperature rise of the water should be within the following range Temperature Rise 27 F 15 C Minimum 36 F 20 C Maximum Note Power Output is affected by the line voltage under load For correct Power Output measurement the line voltage under load must be correct 402s Ovens Pt No 3243522 Issue 6 22 PROCEDURES FOR PRINCIPAL COMPONENTS TEST 1 1 Power Transformer Test You will need A 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 fi
19. All internal electrical connections are correct see wiring diagrams All wiring insulation is correct and is not touching a sharp edge All grounding connections are electrically and mechanically secure All 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 and in the correct order The temperature sensor is correctly connected to the Power PCB Before finishing a service call recheck the following points All of the electronics are functioning correctly and all of the touch pads are working Microwave emissions are below permissible limit of 4 mW cm The power output of the oven is checked in accordance with the procedure page Oven has correct 2 inch 50mm air gap all round and 2 inches 50mm above Air flow should not be restricted 402s Ovens Pt No 3273522 Issue 6 4 PRODUCT SPECIFICATIONS Model Number 4028 VVV FPCRTTZZ Example 402S2086DK3GMUS Model No EC402s 208V 60Hz 2P GND supply MenuKey Revision 3 General Market USA Supply Freq Control Country Voltage Phase Supply Type Rev Type Region rj P RT z Voltage ac Phase Arrangement K GM A General L N E 30 Amp Electronic Market 208 208V a 220 220 230V 11 12 240 230 240V 2 P Gnd 20 Amps D 2 P Gnd 30 Amps Power 208Volts 208V ac 60Hz 30Amp 2P amp G Re
20. Door Choke Plate 105005 Screw M3 Csunk Doorskin 3123094 Door Handle spacer DV0309 Note On Ovens with Serial No s before 000745 WAWA Models External Panels Items 41 42 43 45 47 48 50 51 52 are only available to special order 402s Ovens Pt No 3273522 Issue 6 16 PRINCIPAL COMPONENTS Electronic Control Panel Assembly Version 2 0 2 5 amp WAWA Version 3 0 Note On Ovens with Serial No s before 000745 WAWA Models External Panels Item 51 is only available to special order MenuKey Dust Cover DV0052 Power switch On Off 30 1318 GM Membrane Version 2 0 amp 2 5 DV0055 Membrane WAWA version DV0192 Front Panel Version 2 0 DV0036 Display Assembly amp Header Version 2 0 3021299 MenuKey Socket 11K0005 GM Membrane Version 3 0 DV0254 Front Panel Version 3 0 DV0249 Display Assembly amp Header Version 3 0 30 1324 402s Ovens Pt No 32 3522 Issue 6 17 Part number identification chart 1 Ref No Part No 3021024 Description Cavity High limit Stat Motor Start Capacitor 2uF Blue 3041298 Filter 16 3021340 Air filter SA276 Stirrer motor Assembly SA288 Stirrer inside cavity SA291 5B Stirrer Gear DV0552 os wemmeswema musa EENNL CL CL NN NC 3 o mensae teens r 15 16 Logic PCB Assembly Version 2 0 SA231 6 Logic PCB Assembly Version 3 0 SA260 7 Transformer LT Low voltage 3041155 8 Fuse 1A 3040957 9 Cabl
21. IYWAWV HLYON NI SNIVIN 402s Ovens Pt No 3243522 Issue 6 29 Trouble Shooting Guide Is the problem Food Quality or Fundamental Operational Issue Food Quality Fundamental Standard Food Quality Checks Standard Electrical Checks Check that the PREHEAT temperature is e Check that oven is connected to an set correctly Electricl Power supply and that any trip See User Manual that supplies the unit is not switched off Check that the food being cooked has e Check that the oven is switched on been stored at the correct temperature e Check the Electricl Power supply voltage Check that the correct program is being at the input terminal block used e Check that all fuses are intact e Check that the overheat stat has not Still Have a problem tripped this can be checked by measuring Select a Category the voltage across the Auxiliary transformer Cold Food Page 32 Still Have a problem Core TemperaturesLow Page 32 Select a Category e No Display Page 31 e Cavity Sensor Error Page 33 e Magnetron Over heat errors Page 34 Note The following Diagnosis procedures may not expose all possible errors but have been included for general guidance 402s Ovens Pt No 3243522 Issue 6 30 No Display Is Logic PCB Active See D7 LED Check cable from logic PCB to display is in place and no obvious OFF wires are disconnected or shorted Is Relay PCB Active see D27 Still Have a problem
22. SR EMD FO SSR EMD RR IN m Version 2 5 Part No 31 7067 4 4SD 402s Small Display UK EU FO EMD 1 0 The 402s Control System The control system of the 402s is based upon the following fundamentals Logic PCB Controls and monitors all aspects of the oven and stores all Firmware and Menu Data Fibre Optic Expansion Menus This is where all of the Information for menus is stored It can be changed Firmware This is where all of the oven operating instructions are h stored It can be changed manually or by a MenuKey by a CODEKEY Door Sensor Relay PCB Heater Elements Driven by the Logic PCB the Relay PCB controls all of the power around the oven 402s Ovens Pt No 3243522 Issue 6 46 2 0 How to check your Firmware Version 2 1 Power up the oven and verify the Firmware version that is loaded into the oven OVEN INFORMATION Oven On Time 00028 Hours Magnetron On Time 00000 Hours B E m Door Operations 00049 Software Version 4 1LD MenuKey Code 002 MenuKey Checksum F076 PAUSE Check the Software Version on the Oven Start Up screen and refer to Table 1 below Firmware Verification Table 1 Firmware Version for 402s V3 ovens Abbreviation Firmware Features Supported or lower GM QSR AAAA _ No sereen saver x co emeena 1v wv iv vw tv vf NET Haden eatrreteat x v x co qmm rrefej NE Hiddeneatr
23. TEST 2 e Readings must be below 4mW cm If a level greater that 4mW cm is observed this should be reported to Merrychef Service Division immediately e any case notes should be kept of the leakage that is observed In terms of level and position on the oven This should be kept with the service documentation Test for microwave leakage at all points marked with a lt gt Control Panel A e A EDU Pa 2 8 T t bd TH i E AO gt f F e m S Door Perimeter Door Perimeter Rear Cover vents 402s Ovens Pt No 3273522 Issue 6 21 PROCEDURE FOR POWER OUTPUT MEASUREMENT The power output specification 1500W on this model is established under IEC 705 standard method This method is only workable in Laboratory controlled conditions An approximate method is as follows Ensure the oven is cold before commencing the test Changing the Oven Profile In order to carry out the test the oven PREHEAT must be set to OFF V3 0 or O F V2 0 to switch off the convection heaters and the Manual controls must be set to ON V3 0 or PROGRAM MANUAL V2 0 When the test is completed the oven must be returned to its original settings or the appropriate MenuKey can be used to reset the oven automatically See Appendix 6 for changing the Oven Profile Test procedure 1 Fill one beaker glass or plastic with 2 11 pints one litre of tap water at about 68 F
24. and Manufacturers telephone number 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 DOOR SEAL These ensure a tight seal around the door They should be kept clean and checked regularly for signs of damage Replace if worn or damaged ELECTRICAL SUPPLY CORD Electrical supply cord is situated on the rear of the oven AIR FILTERS Main intake for cooling air for internal components Must be clear of obstructions IMPINGER PLATES Upper amp Lower Direct the air in the cavity They must be cleaned on a regular basis and kept free of debris m STEAM VENT PIPE Vents steam from the oven cavity 402s Ovens Pt No 3273522 Issue 6 MAIN FEATURES Electronic control panel Version 2 0 PREHEAT COOL DOWN FAN SPEED PADS PANEL MenuKey PROGRAM TIME PROGRAM PADS CANCEL PAD Cancels all timed cooking cycles pre programmed operations and stops the microwave energy It does not alter the oven temperature If the oven is hot food will continue to cook and should be removed from the oven immediately This pad will also cancel any incorrect operations It will not erase programs FAN SPEED PADS The Fan speed can be increased and decreased in 5 steps 10 to 100 FUNCTION PADS Move through control functions in the Main Display MAIN DISPLAY PANEL Shows the principal functions o
25. at you comply with the required hygiene standards and will help to maintain and prolong the efficiency of your oven Follow the SAFETY INSTRUCTIONS at the beginning of this manual WARNING DO NOT use caustic cleaners on any part of the oven or oven cavity as it will cause permanent damage to the Catalytic Convertors e ALWAYS switch off at the electrical supply before cleaning e Complete COOL DOWN procedure and allow the oven and accessories to cool before commencing cleaning Hot surface e As required wipe out spillages with disposable Hazard paper wipes Faults arising from neglect or e NEVER use steel wool knives or harsh abrasives USE including Des ue CIE on any part of the oven filters in place are not covered by the guarantee Service visits as a result of such faults will be As with all electrical appliances it is wise to have the chargeable electrical connections inspected periodically AN DO NOT use the oven without clean air filters and cavity grease filter in place START UP OVEN COATING PROCEDURE clean cold oven 1 2 3 4 With the oven clean and Spread Oven Protector Spread Oven Protector Switch the oven ON when cold spray Merrychef lightly onto all internal lightly onto the internal the oven has reached op Oven Protector onto the surfaces of the oven surface of the oven door erating temperature it will sponge take 30 minutes to cure 9 the Oven Protector Note oven protector turns li
26. bre Optic Magnetron Cooling Duct LH Magnetron Cooling Duct RH 402s Ovens Pt No 3243522 Issue 6 13 PRINCIPAL COMPONENTS Back view DV0328 DV0337 DV0058 3041349 SA234 SA208 3071315 3071230 11H0010 DV0039 DV0040 PRINCIPAL COMPONENTS Power Supply Filter 16A 3021340 Fuse 10 HRC 30 0217 Cable Gland 31 0500 Cable Gland Nut 3120499 Electrical Supply Lead Assembly SA217 Terminal Block 3120447 Fuse 20 FLM 30 1177 Fuse Holder 30A 30 1178 Fuse Holder 10 3020231 402s Ovens Pt No 3243522 Issue 6 14 PRINCIPAL COMPONENTS Cavity parts Grease Filter Cartridge Filter Housing Stirrer Glass DV0492 Rack Support V2 5 Not shown DV0114 Upper Impinger plate SA211 Rack V3 0 DV0275 Rack V2 5 DV0158 Lower Impinger plate SA266 Parts 35 amp 37 Contact Service Department KFC Accessories 65 Chicken Griddle SA133 Cool down pan 32 4028 Oven tray MC3175 Handle SA267 Griddle DV0221 Griddle carrier SA350 Chicken Griddle SA350 DV0221 DV0267 SA133 402s Ovens Pt No 3273522 Issue 6 15 PRINCIPAL COMPONENTS External Parts Control Panel BEN ae i u See page 15 32 Description Air Filter SA276 Top Trim DV0187 Rear Panel SA329 Side Panel LH DV0091 Door Skin DVO0501 Door Handle 3271066 Door Inner SA331 Door Choke DV0168 Door Seal DV0305 Bottom Trim DV0037 Side Panel RH DV0092 Door Assembly SA111 Cage Nut
27. e Gland 3120500 Cable Gland Nut 3120499 2 e Heater Element 208V 650W DV0576 Heater Element 220V 650W DV0606 Heater Element 240V 650W DV0607 DV0058 3021349 20 Heater Element Collar 21 Magnetron 22 Magnetron Thermistor Assembly SA234 23 Convection Hot Air Motor Assembly SA208 24 Thermistor Cavity 3041315 25 HV Capacitor 2500V 0 88uF 60Hz Models 3041251 3121261 25 HV Capacitor clip 30 1230 7 Transformer 208 220 240V 60Hz 28 HT Rectifier 11H0010 29 Electrical Supply Lead Assembly SA217 0 Terminal Block 3120447 3041177 C2 Fuse 20A FLM 3021178 C2 2 Fuse Holder 30A 3020231 Q A Fuse Holder 10A 30 Grease Filter 2 parts SA339 SA340 402s Ovens Pt No 3243522 Issue 6 18 Part number identification chart 2 Ref No 36 Part No DV0492 Description Stirrer Glass 3 38 N DV0114 SA211 Rack Support Upper Impinger plate 3 4 Rack DV0275 SA266 Lower Impinger plate 4 Top Trim DV0187 m 65 CM Eur NR Ovens wi ee Serial No s before 000745 s WAWA Models 3071324 Grease Filter 35 Rack 39 41 42 43 45 47 48 75 Relay PCB Fuse 3020470 105005 3123094 DV0309 7 Cage Nut Door Choke Plate 7 N Screw M3 Csunk Doorskin 7 Door Handle spacer Stirrer cover sealant tube 31 0527 SA340 3121247 Grease Filter Cartridge Microswitch interlock spring 402s Ovens P
28. e Oven Profile Page 11 2 Set the Program Mode to ON or OFF 3 Set Manual Mode to ON or OFF 4 Enter the Lower Band temperature setting 15 75 C 5 Set the oven Temperature Scale C WARNING Any programs already Insert a MenuKey and press START to copy the programs on the key will be deleted The display shows the following Copying Programs from Verifying Programs Oven to MenuKey Copied Correctly BEBAR UHL WEE The Display returns to the CATEGORIES screen and the Oven will heat up to the PREHEAT temperature ready to cook MenuKey Copied Successfully 402s Ovens Part N 32 3522 Issue 6 37 APPENDIX 3 Cool Down Procedure To cool down and clean a hot oven EC402s V2 0 EC 402s V3 0 To commence Cool Down procedure Press PREHEAT 0401078 DOWN Place Ice in cavity COOL DOWN MODE COOL DOWN MODE WERL PLACE ICE IN CAVITY PLACE LOAD IN CAVITYAND PRESS START Continue The oven cools down for COOL DOWN MODE COOL DOWN MODE approximately 30 minutes OVEN HOT OVEN HOT PLEASE WAIT PLEASE WAIT Also in Spanish Cycle ends COOL DOWN COMPLETE Turn oven off and ensure READY FOR CLEANING Air Filters are clean Switch oven off ready for cleaning 402s Ovens Pt No 3243522 Issue 6 38 APPENDIX 3 CLEANING 1 For the oven to operate at peak efficiency the cavity door and air filters and grease filter must be kept clean A daily cleaning routine will ensure th
29. f the oven When cooking the time remaining counts down Also displays error messages and oven temperature See TROUBLESHOOTING When storing and recalling a program the display indicates the program number and details Display Panel error messages Message ERROR MAGNETRON 1 ERROR MAGNETRON 2 ERROR MAGNETRON 1 amp 2 CAVITY SENSOR ERROR Cavity temperature exceeds more than 90 F above PREHEAT temperature setting during cook cycle POWER PADS CANCEL PAD FUNCTION PADS MenuKey The MenuKey System automatically changes all the cooking programs with an electronic key and allows program names to be identified POWER PADS The microwave power can be increased or decreased adjusted in 1096 steps 096 to 10096 The default setting is 5096 microwave power PREHEAT COOL DOWN Commences main oven heating cycle to a preset temperature Press and hold for 5 seconds to commence cool down procedure See CLEANING PROGRAM Activates program mode for storing programs in memory START PAD Commences a program TIME PROGRAM PADS These pads are used for setting the cooking time in 1 second steps to a maximum of 10 minutes They are also used for storing and recalling programs from 0 499 Magnetron 1 has overheated Blocked Air filter s Oven located near hot air sources Magnetron 2 has overheated Oven being used empty Cooling fan failure Magnetron 1 and 2 have Magnetron failure overheated Indicates combustion
30. g 555 200009 9 CI of voto OOO00 e e MENUKEY2 DETECTED MK CODE 555 The MenuKey CS e g MK CS 0 06 0A06 Download Upload MenuKey CS checksum confirms the menus on this key 5 valid for the MenuKey Code 4 Download MENUKEY2 DETECTED Confirm that the MenuKey Code MK CODE 555 and MenuKey CS are correct MK CS 0A06 and press Download Function Download Upload key to load the programs into the Oven memory WARNING Note Downloading from a ALL OVEN PROGRAMS MenuKey will clear all the WILL BE OVERWRITTEN existing programs Exit Continue Check that the key is correct O then press the Continue function key to proceed with the Download MENUKEY2 MENUKEY2 DOWNLOADING VERYIFYING HH MENUKEY2 DOWNLOAD On completion of the download COMPLETE press the Exit function key to CHECKSUM 0A06 return the oven to standby mode Exit The display briefly will show the following Oven Model No Software amp MenuKey serial No OVEN COLD Model No 402S The standby screen will then Software PRESS PREHEAT display MK serial No Remove the MenuKey and keep 4 4 5 5 safe place 402s Ovens Part N 32 3522 Issue 6 36 APPENDIX 2 MenuKey Version 3 0 models The MenuKey System automatically changes all the cooking programs on the oven from a pre programmed electronic key To change the menus on the oven Do not remove the key WARNING during do
31. ght brown when cured 402s Ovens Part N 3273522 Issue 6 39 APPENDIX 3 CLEANING 2 e ALWAYS switch off at the electrical supply and allow oven to cool before cleaning e CAUTION Allow the oven and accessories to cool before commencing cleaning WARNING DO NOT use caustic cleaners on any part of the oven or oven cavity as it will cause permanent damage to the Catalytic Convertors Equipment Merrychef oven cleaner Merrychef Oven Protector heat proof gloves protective rubber gloves non abrasive nylon scrub pad cleaning towel and cloths eye protection and dust mask optional COLD OVEN CLEANING INSTRUCTIONS following cool down CAUTION Wear protective rubber gloves when cleaning the oven Oven Parts and filters amp Oven Cavity Remove air filters both sides Wash all parts in warm soapy water Wash off using a clean cloth and plenty of clean warm water Dry using a fresh clean cloth Remove the rack and lift out bottom impinger plate If the door seals are damaged the oven must be repaired by an approved Servicer DO NOT spray directly into the fan opening at the rear of the oven 1 Wear protective rubber gloves and protective glasses carefully spray Merrychef Oven Cleaner onto the internal surfaces of the oven except door seals DO NOT spray directly into the fan opening at the rear of the oven 2 For difficult areas leave to soak for 10 minutes Leave the oven door open during
32. hef It has been prepared to offer technical guidance for the 402s range of 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 attempting to repair the oven check it for microwave emission using a calibrated emission detector 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 MQ Resistor When testing the oven with covers off run for short periods of time only or magnetrons will overheat and the display will show Error condition Before removing any covers from the oven do all of the following e Switch off the mains supply and remove the plug from the wall socket Or e If the oven is hard wired ensure that the power is turned off at the isolator switch Note The On Off switch on the oven is not adequate protection against electric shock as it does not isolate all of the internal wiring from the mains Upon completion of a service the oven or before reconnecting the appliance to the electrical supply for testing check all of the following points
33. ion pads select options shown in the DISPLAY PANEL COOL DOWN PAD Puts the oven into Cool Down Mode prior to cleaning Condition Possible Cause Magnetron 1 has overheated Blocked air filters Ensure air filters are clean Magnetron 2 has overheated Oven located near hot air source Oven being used empty Cooling fan failure Magnetron 1 amp 2 have overheated Magnetron 1 FAILED Magnetron failure Allow oven to cool Magnetron 1 failed No microwave output check power supply Magnetron 2 FAILED Magnetron 2 failed No microwave output check power supply Ambient Overheat exceeded limit Cavity Overheat more than 565 F Temperature inside casing has Cavity temperature has exceeded Blocked air filters Restricted airflow to air filters Oven located near hot air source Circulation fan failure Combustion fire in cavity Blocked air filters Restricted airflow to air filters Combustion fire in cavity Heater Failure Cavity has not reached a One or more heater elements have failed temperature of 100 F in 10 minutes and need to be replaced 402s Ovens Pt No 3243522 Issue 6 Cavity High limit Stat Motor Start Capacitor 2uF Blue Filter 16A Air filter Stirrer motor Assembly Stirrer inside cavity Stirrer Gear Microswitch SW 1 Microswitch SW2 Microswitch Assembly Door Hinge Assembly RH Magnetron Cooling Fan HV Capacitor 2500V 0 88uF 60HZ models HV Capacitor clip Fibre Optic Diode Boa
34. lament 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 See Safety Code Page 4 Isolate the oven from the mains supply Ensure that the High Voltage Capacitor is discharged before commencing work Remove all connections from the Power Transformer Using a D M M check the resistance of the windings Results should be as follows Mains winding between tags Approx 1 1 Q be High Voltage winding Approx 60 Q BONA C Filament winding Less than 1 Q between terminals o Using a Megger test the insulation resistance between Primary winding and chassis Pass if over 10 MO 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 2 High Voltage Capacitor Test You will need A 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 See Safety Code Page 4 1 Isolate the oven from the
35. low the oven to be operated with the door open b Make the following safety checks on all ovens to be serviced before c d activating the magnetron or other microwave source and make repairs as necessary 1 interlock operation 2 proper door closing 3 seal and sealing surfaces arcing wear and other damage 4 damage to or loosening of hinges and latches 5 evidence of dropping or abuse Before turning on microwave power for any service test or inspection within the microwave generating compartments check the magnetron wave guide or transmission line and cavity for proper alignment integrity and connections Any defective or misadjusted components in the interlock monitor door seal and microwave generation and transmission systems shall be repaired replaced or adjusted by procedures described in this manual before the oven is released to the owner e i For U S A A microwave leakage check to verify compliance with the Federal Performance Standard should be performed on each oven prior to release to the owner e ii For CANADA A microwave leakage check to verify compliance with the Canadian Regulation HEALTH AND WELFARE SOR 79 920 should be performed on each oven prior to release to the owner 402s Ovens Pt No 32 3522 Issue 6 3 SAFETY CODE This manual is designed to assist engineers who have been on a recognised product familiarisation and training course run by Merryc
36. me TreLFUse were foarUusE Bozrmo Joonz TRANS MULTI 208220040 2 EA ozrast oseur asoovcapacron 2 e 1 2 2 021293 oroRseeeocowmoueg us 1 ea Br Memoswmonwmumouen ea 2 2 2 mus waGrermow coouncraw 8021298 CAPACHOR MOTORSTART A 1 DISPLAYASSY HERDERVa VBS 1 bozrsts THERMISTOR 150MM LEAD 900MM 1 Bozrss pPoLEROUNDROCKERSWTCH Bum a WAY MAINS TERMINAL BLOCK 1 ea Bux zoso jowmecuwpumae 1 amp 1 2 120827 _ STIRRER cover sealant TUBE 3 mee 3 3 Burr microswren serine mock 1 ea 3 3 zoss poorno o a por gor mw t bwosz MENUKevbusTGOER 1 Dvooss MEMBRANE PANEL v2 25 1 bw DV0305 DOOR SEAL 4028 EN JH X eS oa zx I W NO NO _ gt 180 108 m m gt gt gt gt UIJ NININININITN gt gt IN D cr M m gt gt D N N THE un Q _ W amp W CO ojo jo jo IN oa gt BIND 3a oa N t
37. not exceed meter full scale deflection leakage meter should initially be set to the highest scale then adjusted down as necessary to ensure that low readings are measured on the most sensitive range e To prevent false readings hold the probe on the grip provided and move along the areas indicated on the following page The probe should be moved at 1 inch second 2 5 e With any casework removed the leakage should not exceed 4mW cm e When measuring the leakage always hold the probe at 2inches 50mm from the test area using the probe supplied with the instrument e Always hold the probe at right angles to the oven and point of measurement Procedure Manual Mode 1 Place 0 5 pint 275ml of cold water in the 1 0 Pint 600ml glass iFtheman slmode beaker screen does not Place the 1 0 Pint 600ml glass beaker in the centre of oven appear it must be Set the leakage meter to the appropriate scale range Set a time of 30 seconds with Fan speed at 10 and Power at 100 Press Start and move the survey meter probe along the areas indicated on page 21 Open the door at 30 seconds and taking care change the water If the water boils the meter readings will be inaccurate On completing the test remember to return the Oven Profile and PREHEAT temperature to the original settings 402s Ovens Pt No 3273522 Issue 6 changed in the OVEN PROFILE see Appendix 6 OL coe m 20 PROCEDURE FOR MICROWAVE EMISSION
38. o be adjusted from approximately 1500 rom to 7000 rpm in steps of 5 z 1500 Door Closed not cooking 3500 RPM Door Closed cooking as specified by program or setting Motor Speed and Logic board voltage table Fan Voltage Condition eal U V speed dc IPM e 100 10V 7000 Full Speed amp 3 Power Terminals ees Blue Black Brown 50 5V 3000 Door Closed 20 2V 1500 Door Open Wire 26 Motor Terminals LE 1o Gao P j 1 1 Blue OV Grey wire Yellow 0 10V to Motor Red 10V Displays and messages LED status display LED LED Off Inverter Off No supply Long On amp Off 1sec Power On Ready LED On steadily Inverter Running Long On 0 5 sec short Off General Warning Very Short On amp Off 0 1sec Fault Condition 402s Ovens Pt No 3243522 Issue 6 28 YOLOW YJH ILS NA SHY YOLOW YJ ILS YOLOW NOILO3ANOO EEA LG o 4 m 37189 SYOLOW SNIddV L ADE ASN SADVLIOA MW3HLO TIV N3AO A802 MOd9NIddVLAe023Sn 310ON 64 t n r 77 6c el YAWYOASNVEL ADVLIOA ANY LVLS ALIAVO NOILISOd 035019 NI NMOHS S3HOLIMS ALON AYVAINODAS AYYNIYd EMS SH1 4 gy ZMSSHY 0 Lo sm YOLINOW LMS SHY SMOOTYALNI 9 91551 WVASVIC LINDAIO IN3NW313 Yad LLYM 089 SIN3NW3 T3 3 1LV3H
39. or is located on the Relay PCB Measure the temperature in the area with all the case work in place using a Thermocouple Meter Establish if the magnetron is actually getting hot Remember to take care given the High Voltage in the magnetron area Less than 110 F More than 110 F Temperature reading Check sensor connections Replace Magnetron Check 15 ribbon Cable Cooling Air Flow Problem into control Replace Relay PCB ed Ambient Conditions too hot 402s Ovens Pt No 3273522 Issue 6 34 APPENDIX 1 TEMPERATURE SENSOR RESISTANCE DATA Temperature Sensor Resistance Temp F Temp C Standard Max Rate Rate kQ R 200 C 1 5 Note These resistances will only be apparent in a stable cavity temperature as the sensor has a slow response time 402s Ovens Pt No 3243522 Issue 6 35 APPENDIX 2 MenuKey Version 2 0 models The MenuKey System automatically changes all the cooking programs on the oven from a pre programmed electronic key To change the menus on the oven Do not remove the key during download sequence as this could corrupt the data on the key 1 Ensure the power switch is OFF 2 Lift the MenuKey cover in the top front panel of the oven and put the key in the slot 3 With the key still in place switch the power switch ON The oven will now go through the program download sequence by displaying the following The MenuKey Code e
40. quirements 240Volts 240V ac 60Hz 40Amp 2P amp G Power Output Microwave 100 1500watts Convection 3250watts External 23 0 inches Dimensions 23 0 inches 27 5 inches Weight 198lb s 90kg Construction Cavity 304 Stainless Steel Casework 402s Ovens Pt No 3243522 Issue 6 5 INSTALLATION INSTRUCTIONS Installation Instructions for Mealstream Combination Ovens Power Supply Requirements The Mealstream Series should be connected to a suitable electricity supply which can cope with the switching on surge that occurs with certain types of catering equipment including microwaves Because of this requirement we strongly recommend that a separate suitably rated supply is installed for the oven The supply for the oven should be fitted with a Type C or Time Delay circuit breaker If the oven is hard wired to the supply a double pole isolator switch with a contact gap of at least 1 8 inch 3 mm should be fitted Grounding requirement This appliance must be connected to a grounded metallic permanent wiring system or an equipment grounding conductor should be run with the circuit conductors and connected to the equipment grounding terminal or lead on the appliance Positioning the Oven In order to maintain adequate ventilation for air intake and exhaust and to allow access for cleaning filters you must allow a minimum of 2 inches 50 mm clearance at the sides and rear of the oven
41. rade Version PCB Visual Check Detect to V3 Firmware Blue jumper fitted nid TETTTTTTTTITITI ae es 22323 a 15 n ON V3 ovens 3 0LD or higher board fitted SSR would be fitted if lead is ONLY ON V3 ovens 3 0LD or higher d P BAS M cr A Fibre Optics Board leads fitted V2 V2 5 V3 Hardware Upgrade oven oven oven Adding Magnetron Detect ox TB114 TB114 Adding Solid State Relay ox TB122 TB122 402s Ovens Pt No 3243522 Issue 6 49 4 0 CODEKEY Firmware upgrade Procedure Before commencing an oven Firmware upgrade ensure the oven is switched off 4 1 Insert the appropriate CODEKEY see Matrix 01 on page 2 into the Menukey receptacle on the control panel Lift cover to insert CodeKey into Oven power switch Menukey receptacle 4 2 Warning During the next step the display will be blank for approximately 1 minute DO NOT REMOVE THE CODEKEY DO NOT TURN THE OVEN OFF this will damage the logic board will remain blank for approximately 1 minute before the owitch the oven ON to activate the CodeKey the screen startup screen displays Ci After minute the Oven will boot up immediately press the PAUSE pad to hold the oven information screen OVEN INFORMATION Oven On Time 00028 Hours Magnetron On Time 00000 Hours Door Operations 00049 Software Version MenuKey Code MenuKey Checksum PAUSE gt gt PAUSE pad 402s Ovens Pt
42. rd Solid State Relay 402s Ovens Pt No 3243522 Issue 6 10 PRINCIPAL COMPONENTS Right Side 3041024 3041298 3041340 SA276 SA288 SA291 DV0552 3021294 SA212 SA202 3041295 3041251 3121261 11M0364 3021362 PRINCIPAL COMPONENTS Left Side WARNING For agarst Filter 16A 3071340 Air filter SA276 Stirrer motor Assembly SA288 Stirrer inside cavity SA291 Stirrer Gear DV0552 Microswitch SW3 3071294 Microswitch SW4 Microswitch Assembly SA212 Door Hinge Assembly LH SA203 Motor Controller 3021293 HV Capacitor 2500V 0 88 60Hz models 3041251 HV Capacitor clip 31 1261 Fibre Optic Diode Board 11M0364 402s Ovens Pt No 3273522 Issue 6 11 See Principal components POWER SUPPLY PRINCIPAL COMPONENTS Control Box Fuse 10A HRC Gold resistor 220R Relay PCB Assembly Ribbon Cable 15way Ribbon Cable 10way MenuKey Logic PCB Assembly Version 2 0 Logic PCB Assembly Version 3 0 Transformer LT Low voltage Fuse 1A Sounder Fibre Optic Logic PCB Relay PCB Fuse 402s Ovens Pt No 3273522 Issue 6 12 3020217 30 0235 11K0004 1120298 11M0117 5 231 SA260 3041155 3040957 257 11K0013 3020470 Heater Element 208V 650W 680 Heater Element 240V 650W 880 Heater Element Collar Magnetron Magnetron Thermistor Assembly Each magnetron Convection Hot Air Motor Assembly Thermistor Cavity Transformer 208 220 240V 60Hz HT Rectifier No Fi
43. rmer Piezo sounder output 402s Ovens Pt No 3243522 Issue 6 44 APPENDIX 6 Engineering Test Settings Engineering Test Settings Changing the Oven Profile In order to carry out an oven test procedure the oven PREHEAT must be set to 0 F OFF to switch off the convection heaters and the Manual controls must be enabled When the test is completed the oven must be returned to its original settings or the appropriate MenuKey can be used to reset the oven automatically To set the PREHEAT temperature to 0 F OFF 402s Version 3 0 models 402s Version 2 0 2 5 1 Switch the oven OFF 1 Switch the oven OFF 2 Switch ON and immediately press Edit Preheat 2 Switch ON and Temp immediately press merrychef Edit Preheat to show the ENTER Edit Preheat Preheat Profile PREHEAT TEMP i screen 3 Make a note of the Preheat temperature in 3 Make a note of the Preheat temperature in the the display display 4 Press 0 0 0 to overwrite the current temperature setting ENTER PREHEAT TEMP S O Then press Save to store this setting Press for OFF note pressing either gt gt or lt lt will cycle through all the available temperatures Then Press Save to store this setting To set the Oven controls to allow Manual operation 1 Switch the oven OFF then 1 Switch the oven OFF 2 Switch ON and immediately press the lower right 2 Switch ON and merrychef pad to display the OVEN PROFILE screen
44. rome s x exuviis nee ere ee nee ne NPM Hidden Edt Programs s s aa RAR eo froenn e e e e vv v lo Note this Table excludes KFC France ovens IIf Fibre Optic hardware is fitted Please also be aware of the store you are visiting as this would dictate what version of Firmware they would require See below for clarification CODEKEY Version 4 3LD or lower GM ovens CODEKEY Version 4 4LD QSR ovens All ovens except Quick Service Restaurants Quick Service Restaurants only including Subway and KFC Subway and KFC Note ALL ovens that are lower than 3 0LD Firmware should be up lifted to version 3 0LD or higher depending on what hardware is fitted Refer to Table 2a amp Table 2b 402s Ovens Pt No 3273522 Issue 6 47 3 0 How to check your hardware fitted Z n v ons gt my mi AES s 10 1 Sory 4 s t 1 Y L TE ee e anrd rit peas re a 1 AA f a H 4 E 4 LI Pt mi ot 4 1 1 vy 4 4 2 r a 9 em i r 4 a 25 a LI LII isch RA ASRS E m T Fy rag 4 ijo D j d 2 4 i ee secured to V J 4 n gt 2 E GG LER o v e
45. t No 3243522 Issue 6 19 PROCEDURE FOR MICROWAVE EMISSION TEST 1 Warning Check for radiation emission after servicing Should the emission be more than 4mW cm Inform Merrychef service centre immediately After repairing or replacing any radiation safety device keep a written record for future reference as required by D H H S and Health and Welfare Canada regulation This requirement must be strictly observed In addition the emission reading must be recorded on the service repair documentation while in the customer s premises Please Note Changing the Oven Profile DO NOT attempt to carry out the following procedure unless you have In order to carry out the test the oven PREHEAT the following tools must be set to OFF V3 0 or O F V2 0 to switch off the convection heaters and the Manual controls must be set to ON V3 0 or PROGRAM Tools required for microwave leakage test MANUAL V2 0 1 0 Pint 600ml glass beaker Supply of cold water When the test is completed the oven must be returned to its original settings or the appropriate MenuKey can be used to reset the oven automatically See Appendix 6 for changing the Oven Profile Microwave leakage meter Read and understand all of these notes and procedure before carrying out this operation Note before measuring e Make sure that the survey meter you are using has been calibrated and is suitable for measuring frequencies of 2 450 MHz e Do
46. wnload sequence Downloading from a MenuKey will clear as this could corrupt the data on the key all the existing programs Check that the key has the correct number code for the programs you want to load into the oven memory 1 Ensure the power switch is OFF 2 Lift the MenuKey cover the top front panel of the oven and put the key in the slot 3 With the key still in place switch the power switch ON The oven will now go through the program download sequence by displaying the following Copying Programs from Verifying Programs MenuKey to Oven Copied Correctly TE ETE TET HECE TEE TEE T The display briefly will show the following Oven Model No Software amp MenuKey serial No The Oven will then commence heating up to the PREHEAT temperature ready to cook MenuKey Detected MenuKey Copied Successfully Please Wait h 4 Remove the MenuKey and keep in a safe place Saving Programs to a MenuKey In the CATEGORIES screen select EDIT SCREEN Pad name hidden then select CREATE MENUKEY CAT 001 CATEGORIES CAT 005 GE NE EDIT CAT 002 CAT 006 lt lt EDIT CATEGORY NAME EDIT A PROGRAM gt gt 003 007 CREATE MENUKE CAT 004 V CAT 008 ME a Y 0 EDIT SCREEN Enter a number for the MenuKey Code to identify Sa the new Menukey use the Function Pads f P ee For an explanation of the following features see Setting th
47. z ta du gt E Li j um EA B A ner j In d L Bat er J D 4 j pete a 17 sc AE z Lu afe CH Ew TC i LIT J UE TIE B m a Legs o 18 2 tt Ae ww c 5 a RIBIS P ER z no MEE r F U st ta D pe p e A 36 11 710 6200 l Y k RP url de M 131531 I 5 Y IAY ES o wv eT 4 t EI IC d 3 J Lt ta 2 1 ii S m E 1 9 Tn E 5 4 i Sir E i 3 ma 1 M 00 E 4 Fir LG LAN 2 ae 4 AES Li prm 3 S f HT 4 2 2M Izd T alp En r Iu i gt z Peed iT aik nc E S C j 1 3 1 Remove the oven lid to reveal the Logic PCB See Table 2a below Hardware fitted TABLE 2A against PCB visual Mag PCB Visual Check SSR Device free standing Supports Oven Upgrade Technical Bulletin Required V2 V2 5 oven oven Adding Magnetron Detect ox TB114 NL 402s Ovens Pt No 3273522 Issue 6 Adding Solid State Relay 48 V3 oven TB114 TB122 Allowable Version Firmware ONLY ON V2 ovens 4 4SD ON V2 5 ovens 4 4SD or higher ON V3 Ovens 3 0LD or higher UOISIA9M Hardware fitted TABLE 2A against PCB visual Supports Oven Allowable SSR Mag Upg
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