Service manual

ManualsBrandsMerrychef ManualsKitchen AppliancesMealstream 400 Series

Mealstream Ovens Pt. No. 32Z3403 Issue 15

Page 1

CAUTION MICROWAVE EMISSIONS

DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE GENERATOR

OR PARTS CONDUCTING MICROWAVE ENERGY

Mealstream

SERVICE

SERVICE MANUAL

ALL CTM3 MODELS & TIM HORTON'S COMBINATION OVEN

MANUFACTURED FROM JANUARY 2003

Summary of content (52 pages)

PAGE 1
SERVICE ALL CTM3 MODELS & TIM HORTON'S COMBINATION OVEN MANUFACTURED FROM JANUARY 2003 SERVICE MANUAL Mealstream CAUTION MICROWAVE EMISSIONS DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY Mealstream Ovens Pt. No.
PAGE 2
TABLE OF CONTENTS Microwave safety precautions................................................. 3 Safety code ............................................................................. 4 Product specifications ............................................................. 5 Installation instructions............................................................ 6 Main features ....................................................................... 7-8 Principal components: LHS................................
PAGE 3
MICROWAVE SAFETY 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 allow the oven to be operated with the door open. (b) Make the following safety checks on all ovens to be serviced before 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).
PAGE 4
SAFETY CODE This manual is designed to assist engineers who have been on a recognised product familiarisation and training course run by Garland. It has been prepared to offer technical guidance for the Mealstream 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.
PAGE 5
PRODUCT SPECIFICATIONS Model Number: + Voltage + Frequency + Phases + Controls + Country Model No. CTM3 Voltage Frequency Phases 208V 20 240V 24 50Hz 50 60Hz 60 Single 1 Three 3 Control Type Series 5 S5 Country UK UK Customer Variant N.America A N.America TH = Tim Hortons Power Requirements 208Volts 240Volts Power Output Microwave 100% 1425W Convection 3000W Combination 1425W + 3000W External Dimensions Height 30 inches ( 765mm ) Width 29.
PAGE 6
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.
PAGE 7
MAIN FEATURES a b b c f g d j i e h k a On/Off SWITCH f HOT AIR FAN This is used to turn the oven On or Off. IT DOES NOT ISOLATE INTERNAL WIRING FROM THE MAINS SUPPLY. b EXHAUST VENTS Allows exhausted air from the magnetron cooling system to escape. c OVEN CAVITY The oven cavity is mainly constructed from stainless steel panels. It must be kept clean.
PAGE 8
MAIN FEATURES Electronic control panel a b j i h g f a Stage LED's b Program & Time Display e Convection Pad f Power Pads g Time / Preset Pads h Temperature Set Pads i Cancel / Callback Pad j Program Pad N Menukey™ Tim Hortons control panel a M N e b N MENU KEY K L K Preheat L Cancel M Icon Cook Pads N MenuKey™ O Quarter, Half & Full Batch Load M Mealstream Ovens Pt. No.
PAGE 9
PRINCIPAL COMPONENTS Left side 1 1A 2 2A 3 3A 4 4A 5 5A 13 6 12 14 7 11 8 10 9 No Description 208V 240V 1 Fuse holder 30Z0231 30Z0231 1A Fuse 10 amp 30Z0217 30Z0217 2 Fuse holder 30Z0231 30Z0231 2A Fuse 10 amp 30Z0217 30Z0217 3 Fuse holder 30Z0285 30Z0285 3A Fuse 1 amp 30Z0957 30Z0957 4 Fuse holder 30Z1178 30Z1178 4A Fuse 20 amp 30Z1177 30Z1177 5 Fuse holder 30Z1178 30Z1178 5A Fuse 20 amp 30Z1177 30Z1177 6 Electrical supply terminal block 31Z
PAGE 10
PRINCIPAL COMPONENTS Right side 95 22 21 59 15 20 90 16 No 17 18 19 Description 208V 240V 15 Door arm assembly 11C0300 11C0300 16 Door hinge assembly ( RH )B 11C0166 11C0166 17 Micro-switch ( Secondary ) 30Z0240 30Z0240 18 Door arm stop assembly 11C0279 11C0279 19 Door spring 520000 520000 19 Door spring( Long )A 40C1141 40C1141 20 Steam pipe 40C1023 40C1023 21 Steam vent guard 790061 790061 22 Temperature sensor 50E123 50E123 59 Rubber stop 31Z1150 31Z115
PAGE 11
PRINCIPAL COMPONENTS Top view 60 61 87 87 23 23 24 24 63 63 26 26 27 27 62 28 No Description 208V 240V 23 Magnetron (Panasonic) 30Z1171 30Z1171 24 Resistor 470 R 30Z0283 30Z0283 26 Capacitor 0.88µf (2300V)A 30Z0861 30Z0861 26 Capacitor 0.
PAGE 12
PRINCIPAL COMPONENTS Back view 94 104 105 Description 208V 88 64 65 No 240V 64 Hot air motor assembly 11C0312 11C0312 65 Capacitor 6µF 30Z1148 30Z1148 88 Overheat Safety Thermostat 30Z1024 30Z1024 94 Hot Air motor Resistor 50R N/A 30Z1165 104 Twin Blower Resistor 39R N/A 30Z1164 105 Twin Blower Resistor 50R N/A 30Z1165 Mealstream Ovens Pt. No.
PAGE 13
PRINCIPAL COMPONENTS 86 Door and cavity roof 67 86 72 106 107 77 108 109 71 89 76 No Description 208V 240V 101825 101825 53 M5 Hex/hd s/s Screw 67 Stirrer glass assy. ( inc.
PAGE 14
PRINCIPAL COMPONENTS 70 Heater Element and Cavity parts 103 69 92 57 68 102 92 70 85 No Description 208V 240V 57 Mesh washer 31Z5044 31Z5044 68 Heater element 40C0949 40C0948 69 Heater element cover plate 790047 790047 70 Baffle 11C0311 11C0311 85 Dome Nut 80X7025 80X7025 92 Tray Support 40C0950 40C0950 102 Hot Air Impeller MC3111 MC3111 103 Hot Air Impeller Securing Nut 105065 105065 External Parts and accessories 98 96 100 101 97 110 99 No Description 20
PAGE 15
PRINCIPAL COMPONENTS Electronic Control Panel Assembly 29 34 33 32 31 73 No Tim Hortons See page 16 30 Description 208V 240V 29 On/Off Switch 30Z0503 30Z0503 30 Control Panel Assy with Menukey (except Tim Hortons) 11C0379 11C0379 31 Logic Board (except Tim Hortons) 11C0377 11C0377 32 Relay Board (except Tim Hortons) 11C0316 11C0212 33 AC Ribbon connector 11M0116 11M0116 34 DC Ribbon connector 11M0117 11M0117 73 MenuKey Assembly 10C0148 10C0148 Mealstream Ovens Pt.
PAGE 16
TIM HORTONS CONTROL PANEL US/ English No Description 208V 240V 30 Control Panel Assy with Menukey 11C0332 11C0332 31 Logic Board 11C0331 11C0331 32 Relay Board 11C0316 11C0212 208V 240V US/ English 1/4 Load No Description 30 Control Panel Assy with Menukey 11C0412 11C0412 31 Logic Board 11C0411 11C0411 32 Relay Board 11C0402 11C0403 208V 240V French Canadian No Description 30 Control Panel Assy with Menukey 11C0413 11C0413 31 Logic Board 11C0411 11C0411 32 Rel
PAGE 17
PRINCIPAL COMPONENTS ( not shown in main views ) 12 Left Hand Door Hinge Assembly 16 52 52 51 51 55 56 Right Hand Door Hinge Assembly 54 54 53 53 Motor shaft screen and seal assembly 49 Stirrer motor assembly 58 50 No.
PAGE 18
PRINCIPAL COMPONENTS Input wiring details 6 Green/Yellow L1 L2 Black Green White 48 47 46 No Description All models 6 Electrical Supply Terminal Block 31Z0149 46 Cable Gland 31Z0500 47 Gland Nut 31Z0499 48 Electrical Supply Cord 3 Core 30Z1162 91 Electrical Supply Plug 50Amp (Canada) 31Z0298 Mealstream Ovens Pt. No.
PAGE 19
PRINCIPAL COMPONENTS: Part Number Identification Chart 1 Part No No Description 208V 240V Page No 1 Fuse holder 30Z0231 30Z0231 9 1A Fuse 10 amp 30Z0217 30Z0217 9 2 Fuse holder 30Z0231 30Z0231 9 2A Fuse 10 amp 30Z0217 30Z0217 9 3 Fuse holder 30Z0285 30Z0285 9 3A Fuse 1 amp 30Z0957 30Z0957 9 4 Fuse holder 30Z1178 30Z1178 9 4A Fuse 20 amp 30Z1177 30Z1177 9 5 Fuse holder 30Z1178 30Z1178 9 5A Fuse 20 amp 30Z1177 30Z1177 9 6 Electrical supply terminal block
PAGE 20
PRINCIPAL COMPONENTS: Part Number Identification Chart 2 Part No No Description 208V Page No 240V 46 Cable Gland 31Z0500 31Z0500 18 47 Gland Nut 31Z0499 31Z0499 18 48 Mains Cable 3 Core 30Z1162 30Z1162 18 49 Motor shaft screen 40C1005 40C1005 17 50 Hot air motor damper/seal 40C1008 40C1008 17 51 Pin 52 Roller 53 M5 Hex/hd s/s Screw 54 M5 stainless steel Nut 55 56 57 790027 790027 17 40C0752 40C0752 17 101825 101825 80X7003 80X7003 17 LH Hinge bracket 790024
PAGE 21
PRINCIPAL COMPONENTS: Part Number Identification Chart 3 Part No No 96 Description 208V 240V Page No Side Panel Left Side 790002 790002 14 97 Side Panel Right Side 790003 790003 14 98 Top Panel 790005 790005 14 99 Foot 32Z1052 32Z1052 14 100 Wire Shelf 40C1011 40C1011 14 101 Crumb Tray RBR290X02 RBR290X02 14 102 Hot Air Fan MC3111 MC3111 14 103 Hot Air Fan Securing Nut 105065 105065 14 N/A 30Z1164 12 104 Twin Blower Resistor 39R 105 Twin Blower Resistor 50R
PAGE 22
PROCEDURE FOR MICROWAVE LEAKAGE TEST (1) Warning Check for radiation leakage after servicing. Should the leakage be more than 4mW/cm² Inform Garland 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 leakage reading must be recorded on the service repair documentation while in the customer’s premises.
PAGE 23
PROCEDURE FOR MICROWAVE LEAKAGE TEST (2) • Readings must be below 4mW/cm². If a level greater that 4mW/cm² is observed, this should be reported to Garland Service Division immediately. • In 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. Control Panel Door Perimeter Rear and Side Covers Left & right Side Air Filters.
PAGE 24
PROCEDURE FOR POWER OUTPUT MEASUREMENT The power output specification, 1425W 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. Tim Hortons Ovens To carry out this test the Icon Pads need to be switched to ENGINEERING MODE PROGRAMS See Appendix 1 1 Fill one beaker ( glass or plastic ) with one litre ( 1.78 pints ) of tap water ( at about 68ºF/ 20ºC ) and measure the water temperature.
PAGE 25
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 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.
PAGE 26
PROCEDURES FOR PRINCIPAL COMPONENTS TEST (2) 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.
PAGE 27
PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST (1) The door on the Mealstream oven is monitored by three microswitches. These are used in the conventional “Primary, Secondary and Monitor” switch arrangement shown below. The switches operate as follows: Door Interlock Arrangement L1 Primary switch 11 Switches shown in Door Closed position Secondary switch 17 Power Out Power In L2 Monitor switch 14 1. Monitor switch ( 14 ,Top left-hand Side ).
PAGE 28
PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST (2) Please Note DO NOT attempt to carry out the following procedure unless you have the following tools and parts. Continuity Meter Spacer Door Spacer Kit Part No. 10C0171 No. required Part No.
PAGE 29
PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST (3) Step 2: Insert S10 10mm spacer into door. (See figure 1 below for inserting spacer correctly). Interlock Step 3: Remove S10 10mm spacer and insert S1 1mm spacer into the door and close the door. Step 4: Remove S1 1mm spacer and insert S5 5mm spacer into the door and close the door.
PAGE 30
PROCEDURE FOR BUILDING AND FITTING MEALSTREAM DOOR Parts required for door fitting Please Note DO NOT attempt to carry out the following procedure unless you have the following tools and parts. Item No. Description Part No.
PAGE 31
PROCEDURE FOR BUILDING AND FITTING MEALSTREAM DOOR 1. Visually check all parts to be used. 2. Fit right hand side (RHS) Hinge assy. to base assy. loosely fit in place with bottom bolts, 2 off M5 x 10mm, 2 off M5 flat washer, 2 off M5 shockproof washer. Fit spacer to fill gap between Hinge assy and Inner side panel, loosely fit spacer in place with 1 off M5 bolt x 16mm, 1 off M5 flat washer, 1 off M5 shakeproof washer. Spacer Hinge fixings 3. Insert (RHS) Pivot pin of door frame into (RHS) Hinge assy.
PAGE 32
PROCEDURE FOR BUILDING AND FITTING MEALSTREAM DOOR 5. Fit door frame assembly (including seals and cage nuts) firmly against cavity and tighten all fixing bolts to secure (RHS) and (LHS) Hinge assy. Hinge 6. Position door frame central by using the following method. Measure the distance between the side of the door and the TDK Mounting Strip on both sides with the door in the closed position. Add these two measurements together and divide by 2.
PAGE 33
PROCEDURE FOR BUILDING AND FITTING MEALSTREAM DOOR 9. Position door choke to Door Frame Assembly making sure it is in the correct orientation (the top of door choke is marked with ‘T‘ on the underside). ‘T’ Mark Stage 2 Stage 1 10. Loosely fit 3 off M5 flat washers, 3 off M5 shockproof washers, and 3 off M5 stainless steel full nuts. 1 11. Tape choke Spacer S325 to the cavity base and tape choke Spacers S215 to sides and top of door choke. Close the door and centralise the door choke.
PAGE 34
PROCEDURE FOR BUILDING AND FITTING MEALSTREAM DOOR 12. Fold the square piece oven insulation in half and place it in the recess in the oven door. Place the rectangular piece into the remainder of the door (foil facing out). Stage 1 13. Place the outer skin over the door frame assembly and fix with 7 of M3x12 counter sunk screws around the LHS, RHS and top of the door. Please note. It is very important after completing this procedure, to carry out a Door interlock adjustment and test procedure.
PAGE 35
PROCEDURE FOR REPLACING DOOR SEAL ASSEMBLY (1) Parts required for replacing carbon loaded door seals Please Note DO NOT attempt to carry out the following procedure unless you have the following tools and parts. Item Description Part Number Quantity 1 Door seal set of 4 11C0292 1 2 CAF 30 ( Black ) 31Z0186 As required Tools required for replacing carbon loaded door seals Long nose pliers Adhesive skeleton gun Flat head screw driver Please note.
PAGE 36
PROCEDURE FOR REPLACING DOOR SEAL ASSEMBLY (2) Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Please note. It is very important after completing this procedure, to do a Door interlock adjustment and test procedure. See pages 27-29. Mealstream Ovens Pt. No.
PAGE 37
PROCEDURE FOR REMOVING SHELF RUNNERS AND ELEMENT COVER PLATE Please Note DO NOT attempt to carry out the following procedure unless you have the following tools. Tools required for removing shelf runners and element cover plate. M6 nut runner M5 nut runner M5 stainless steel dome nut Pt. No. 80X7025 M6 x 12mm stainless steel Hex Head screw Pt No. 80T7133 Element cover plate Shelf runner 1. Loosen the rear fixings screws of both shelf runners with M6 nut runner. 2.
PAGE 38
PROCEDURE FOR REPLACING HEATER ELEMENT Please Note DO NOT attempt to carry out the following procedure unless you have the following part and tools. Parts required for replacing heater element. Item Description 1 Heater Element 2 Mesh Washer Part Number Quantity 208 volt 40C0949 / 240 volt 40C0948 1 31Z5044 3 Tools required for replacing heater element. M5 nut runner 1. Disconnect or isolate oven from mains supply. 2. Remove outer covers. 3.
PAGE 39
PROCEDURE FOR REPLACING HOT AIR MOTOR ASSEMBLY Please Note DO NOT attempt to carry out the following procedure unless you have the following part and tools. Parts required for replacing hot air motor assembly. Item Description 1 Hot Air Motor Assembly Part Number Quantity 11C0312 1 Tools required for replacing hot air motor assembly. M5 nut runner 1. Disconnect or isolate Oven from mains supply. 2. Remove outer covers. 3. Remove shelf runners and element cover plate (See page 37). 4.
PAGE 40
PROCEDURE FOR REPLACING MAGNETRON ASSEMBLY (1) Parts required for replacing magnetron Please Note DO NOT attempt to carry out the following procedure unless you have the following tools and parts.
PAGE 41
PROCEDURE FOR REPLACING MAGNETRON ASSEMBLY (2) Figure 1 - 6 Figure 2 Figure 1 Magnetron connection block Temperature Stat. Screw Figure 3 Figure 4 Temperature Stat. Screws 4 x Magnetron screw fixings Figure 5 Temperature Stat. Figure 6 Magnetron mount Wire mesh Please note. After completing this procedure do a microwave leakage test. See page 22-23. Mealstream Ovens Pt. No.
PAGE 42
PROCEDURE FOR TESTING MEMBRANE PANEL CIRCUIT You will need: A Digital Multi-meter (D.M.M.) 1. The oven isolate from the electrical supply. 2. Remove the Logic Assembly from the Control Panel Housing. 3. Unplug the membrane “tail” from the Logic PCB Assembly. 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 circuit. 1 10 Mealstream 501 US Mealstream Ovens Pt. No.
PAGE 43
PROCEDURE FOR TESTING MEMBRANE PANEL CIRCUIT (2) Mealstream 501 US Tim Hortons & Unbranded Variant Note:PINS 1-4 Lower Layer & Pins 5-10 upper layer Mealstream 501 US Tim Hortons French (Canada) Note:PINS 1-4 Lower Layer & Pins 5-10 upper layer Mealstream Ovens Pt. No.
PAGE 44
Mealstream Ovens Pt. No. 32Z3403 Issue 15 Page 44 30Z1177 30Z1177 30Z1177 30Z1177 CIRCUIT DIAGRAM: ALL MODELS BEFORE 05.28.
PAGE 45
CIRCUIT DIAGRAM: ALL MODELS AFTER 05.28.02-11.10.02 Mealstream Ovens Pt. No.
PAGE 46
Mealstream Ovens Pt. No.
PAGE 47
CIRCUIT DIAGRAM: ALL MODELS AFTER 04.06.03 Mealstream Ovens Pt. No.
PAGE 48
ERROR CODES AND DIAGNOSTICS The Mealstream will identify some of the most common problems by flashing an error message code in the time display window. These are the error messages, and suggestions for repairing them. 1 Door not fully shut. Close door fully. 2 Possible electrical fault Door switch inoperative. 3 Magnetron overheating. Check air filters. Check location, air inlet temperature and air filters. 1 No time has been set. Set a time. 2 Invalid time has been set. Set a valid time.
PAGE 49
APPENDIX 1 Tim Hortons variants: Power Test and Microwave Leakage Test (Pages 22-24) Engineering Mode programs In order to carry out the Power Test and Microwave Leakage Test on Tim Hortons variant Ovens, the Icon Pad programs on the control panel need to be switched to Engineering Program Mode. Engineering Mode does not affect the current Menukey program settings for the Icon pads and the current Menukey programs are automatically restored when the oven is next switched on.
PAGE 50
APPENDIX 2: 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 Lift the MenuKey™ cover in the top panel of the oven and put the key in the keyhole Turn the key clockwise to the stop ( ¼ turn ). Do not remove the key at this stage. 3 Switch the power switch on.
PAGE 51
APPENDIX 3: TEMPERATURE SENSOR RESISTANCE DATA Temperature Sensor Resistance Temp °F Temp °C Min. Rate kΩ Standard Rate kΩ Max. Rate kΩ 212 100 11.490 13.060 14.810 302 150 2.803 3.161 3.434 392 200 0.950 1.000 1.050 482 250 0.3572 0.3865 0.4171 R(200)°C = 1 kΩ ± 5% Note: These resistances will only be apparent in a stable cavity temperature as the sensor has a slow response time. Mealstream Ovens Pt. No.
PAGE 52
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.