Mealstream 400 SERIES SERVICE MANUAL Part No. 32Z3769 Issue No.
Table of Contents Safety Code ...................................................................................................3 Product Specifications ...................................................................................4 Installation Instructions ..................................................................................5 Electrical Installation ......................................................................................6 Error Codes and Diagnostics........................
SAFETY CODE This manual is designed to assist engineers who have been on a recognised product familiarisation and training 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.
Product specifications: Mealstream 401 & 403 models ELECTRONIC CONTROLS: ( EC401 & EC403 models ) Model No.: 1003 + Voltage + Frequency + Current + Controls + Phase + MenuKey + Catalytic converter For example: Model prefix 1003 100345XE52MK 230-240V, 50Hz, 30A, Series 5 Controls, Twin Phase, MenuKey Voltage Frequency Current 2 = 220-230V a.c. 5 = 50 Hz EE = 13A 4 = 230-240V a.c.
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(2 inches) clearance at the sides and rear of the oven, and at least 150mm above. Air intake temperature should not exceed 35°C (95°F). Excessive temperature will lead to reduced operating duty cycle or premature ageing of internal components.
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 WARNING 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.
Error codes and diagnostics Electronic Control Models The control panel will identify some of the most common problems by flashing an error message code in the time display window. Possible Cause Service 1 Door not fully shut Close door fully.
Main features b d c e p g f h q n j l rear view of Oven k m b VENTS c TRAY HANDLE RESTS There is one on each side of the 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. CATALYTIC CONVERTOR Allows extraction free cooking. Should be removed regularly for cleaning.
Electronic controls: a Stage LED's b Service Indicator a c Air Filter Block Indicator b e Program Display c f Temperature Set Pads g Time / Program Number Pads h Cancel/ Callback Pad i Program Pad j Convection Pad k Microwave power Pads l On/Off switch e m f MenuKey socket g i h j k l 400 Series Ovens 32Z3769 Issue 1 m Page 9
Procedure B - Simplified Power Output Test for Field Service Use You will need: A thermometer capable of reading to ±0.1°C. A Polypropylene tray approximately 200 mm x 200 mm. A measuring jug. A calculator. Water which is at a temperature of 10°C ± 2°C. 1 2 3 4 5 6 7 8 Procedure A - Power Output Test In accordance with BS EN 60335-2-90 is not used in the field please Engineers Procedure B. Measure 1 litre of cold water into the tray using the measuring jug.
Procedure D - 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 .
Door interlock operation The door on the oven is monitored by five 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 and the fifth switches the power to the convection motor.
Procedure for Door Interlock and test: WARNING Before adjusting the microswitch assemblies ensure that the oven has been isolated from the electrical supply and discharge the HT Capacitors. Please note the terminals on the microswitches remain live when the oven is switched off, so complete isolation is essential. Tools Required: Door Spacer Kit P10H0129, Multimeter The purpose of this procedure is to set the interlock so that when the door is opened more than 3mm the Oven microwave circuit is switched OFF.
3 Remove the 3mm spacers and open and close the door 2 or 3 times to allow the parts to work together. Set a Multimeter Resistance [ Ω ] and connect the meter to the microswitch terminals 37 & 29. Replace the 3mm spacers on the door and over the corners of the seal as before. 3mm Spacers Open Circuit Door Seal Door The meter should now read open circuit, if not repeat steps 1 & 2 adjusting the switch assemblies slightly upwards, ensuring the Microswitches are in the OPEN [OFF] position.
Principal components: casework 4 3 2 6 1 7 104 2 96 8 12 9 105 11 140 MC3134 9 Handle Hanger RMC6773 11 Front Lower Panel MC3047 MC3120MC 12 Lower Trim MC3122 RMC6759EMC 96 PCB Retainer 40H0084 MC3769MC 104 Side Trim LH MC3789MC 105 Side Trim RH MC3121 140 Rubber Base seal long Rubber Base seal short 40H0259 40H0260 1 Side Panel (L/H) 2 Ferrite 3 Upper Trim 4 Top Plate 6 Rear Panel 7 Air Filter MC3155 8 Side Panel (R/H) MC3145 400 Series Ovens 32Z3769 Issue 1
Door mechanism 13 Door Stay (R/H) 14 Hinge Body 15 Hook (A) RMC66171 16 Hook (B) RMC66172 17 Door Spring (B) 18 Hinge Body (L/H) 19 Door Spring (A) MC3067 20 Door Stay (L/H) MC3046 22 Solid Door Assy Silver 400 Series Ovens 32Z3769 Issue 1 MC3040 MC30121X02 MC3068X01 MC30122X01 MC3230MCX02 Page 16
Oven cavity components and hot air system Catalytic Converter 137 136A 135 25 23 Turntable Disc RMC7340X01 34 Motor Bracket RMC7307X01 24 Baffle Plate Bolt CP30326 37 Convection Motor MC3730MOD 25 Baffle Plate MC3018 135 Catalytic Converter 26 Fan Fixing Cap RCK7617 27 Convection Fan MC3111 30 Oven Body 31 Gearbox 32 Shaft 33 Motor Cooling Fan 136A Vent Plate 137 Thumb nut 31Z1245 40H0236 31Z4031 MC3750MC MC3216 RMC7391X01 400 Series Ovens 32Z3769 Issue 1 RMC7310 P
Oven door assembly 49 22 Solid Door Assy.
Door Interlock RHS, Magnetron & Stirrer Motor 129 133 54 Door Switch Bracket 40H0023 61 Foam Tape 31Z0042 55 Microswitch SW4 30Z0240 63 Magnetron 30Z1349 56 Microswitch SW5 30Z0240 64 Magnetron Thermal trip 30Z0088 59 Microswitch Insulator 31Z0115 129 Turntable Motor 11H0110 60 Outlet Duct MC3037 400 Series Ovens 32Z3769 Issue 1 Page 19
Principal Components LHS & Rear view: Microswitches 138 139 57 117 57 Secondary Microswitch SW3 30Z0240 117 Axial fan 11H0075 138 Primary Microswitch SW2 30Z1396 139 Monitor Microswitch SW1 30Z1395 142 55 56 74 73 143 37 37 Hot Air Motor 55 Microswitch SW4 30Z0240 56 Microswitch SW5 30Z0240 69 Thermal cut-out switch 30Z1024 73 Heater Element 240V 40H0009 74 Temperature Sensor 30Z1419 142 Exhaust steam pipe 143 MC3730MOD Note: 1.
Principal Components RHS 1 : Models _ EE5, _ XE5, [CD2] 71 70 60 90 128 76 76A 117 60 Outlet Duct 70 Bridge Rectifier 71 No. 8 Screw 31Z3107 76 HT Capacitor 0.
Principle components RHS 2: _ EE5, _ XE5 75 HV Diode Assembly 76 HT Capacitor 0.
Principle components RHS 3: _ XX5, _XX52 140 130 128 90 117 90 76 76A 76 HT Capacitor 0.75uF 2500V 76A Capacitor Clip 30Z1329 30Z1261 90 Transformer 208-240 60Hz 30Z1233 117 Axial Fan 11H0075 128 Cooling Fan 208V 50Hz 30Z1128 130 Diode Board 11H0058 140 Potentiometer 1 11H0058 Note: 1.
Input wiring, filters and fuses 1 Model 1003__XE5, XD5 Model 1003__EE5, CD2 Green / Yellow Green / Yellow Blue Blue Brown 111 112 112a 115 111 116 Model: UK 113 Cable Assembly 111 Mains Input Block 31Z0328 113 _ EE, _CD2 10H0012 112 Cable Gland 31Z1070 113 _XE5 [Single phase] 10H0011 112A Cable Gland Nut 115 XE5 Input Cable Assembly 116 Strain Relief Grommet 31Z1082 302030 Europe 113 _XE5 [Single phase] 10H0064 31Z1036 82 78 79 81 77 80 79 81 77 Microwave Mains Filte
Input wiring, filters and fuses 2 Model RMC1003__XX5, XX52 Green / Yellow Green / Yellow Blue Blue Brown L2 L1 111 112 112a 115 111 Model: UK 115 Cable Assembly 111 Mains Input Block 31Z0328 115 _ XX5 [Single phase] 10H0046 112 Cable Gland 31Z1070 115 _XX52 [Twin phase] 10H0039 112A Cable Gland Nut 31Z1082 Europe 113 Input Cable Assembly 31Z0220 115 _XE5 [Single phase] 10H0065 116 Strain Relief Grommet 31Z1036 115 _XX52 [Twin phase] 10H0063 78 77 82 81 80 81 77 Microwa
Control Panel 1: Electronic controls assembly 100 102 110 99 101 98 107 95 108 103 107 109 110 97 98 131 97 95 95 Membrane Assy See table 97 On/Off Switch 30Z0503 Model 98 Logic Assy. See table EE5, XE5, XX5 11H0060 99 Support Shield 40H0075 XX5 Starbucks 11H0024 100 M3 x 5 Screw 31Z3106 EE5, XE5, XX5 Menukey 11H0067 101 No.
Control Panel 2: Membrane panel circuit You will need: A Digital Multi-meter (D.M.M.) 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.
Control Panel 3: Manual control assembly 96 123 124A 121 124B 124C 124D 122 125 105A 126 97 123 96 PCB Retainer LH 40H0084 97 On/Off Switch 30Z0503 105A Side Trim RH MC31212 106 M5 Flat Washer 31Z5004 121 PCB Assembly 11H0027 122 Timer 30Z0991 123 Amber Neon 316031 124A Control Knob Black 313020 124B Control Knob Skirt Red 313160 124B Control Knob Skirt Blue 31Z1216 124C Control Knob Cap Red 313220 124C Control Knob Cap Blue 31Z1217 124D Control Knob Shaft Adaptor 11C
Part number identification chart 1 1 SIDE PANEL (L/H) MC3134 41 INNER INSULATION PANEL 2 FERRITE 3 UPPER TRIM 4 TOP PLATE 6 REAR PANEL 7 RMC6773 42 DOOR REINFORCEMENT MC3120MC 43 DOOR FRAME (B) MC3055 RMC6759EMC 44 INSULATION WRAP 32Z0001 MC3769MC 46 DOOR BASE SILVER MC3031X05 AIR FILTER MC3155 47 DOOR COVER MC3064X01 8 SIDE PANEL (R/H) MC3145 48 PLATE - DOOR SWITCH RHS MC3056 9 HANDLE HANGER RCK6319 49 PLATE - DOOR SWITCH LHS MC0562MC 11 FRONT LOWER PANEL MC3
Part number identification chart 2 77 M’WAVE MAINS FILTER 16A 78 MAINS FILTER 16A 81 FUSE HOLDER 30Z1178 104 PCB Retainer RH 40H0084 82 FUSE 20A 30Z1177 121 PCB Assembly 11H0027 90 TRANSFORMER 208-240V 50Hz 30Z1233 122 Timer 30Z0991 95 MEMBRANE ASSEMBLY See table 123 Amber Neon 316031 96 PCB RETAINER 40H0084 97 ON/OFF SWITCH 30Z0503 124A Control Knob Black 313020 98 LOGIC ASSY.
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 Lift the MenuKey cover in the front 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.
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 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.
RECOMMENDED PARTS LIST: 240V 50Hz Models _EE5, _XE5, CD2, 400 Series Ovens 32Z3769 Issue 1 Page 33
RECOMMENDED PARTS LIST: 240V 50Hz Models _XX5, XX52 400 Series Ovens 32Z3769 Issue 1 Page 34
400 Series Ovens 32Z3769 Issue 1 NEUT N(3) L(1) 10 AMP FUSE 1 FUSE 2 13 AMP N(3) L(1) FILTER 2 14 U(4) U(2) 33 pb AC AC 12 1 SW1 LHS TOP REAR MONITOR 30 BLOWER ASSY JP2 29 HOT AIR FAN 28 2 18 JP1 64 1 RL1 SOFT MAGNETRON CUT-OUT SHORTING LINK 19 SW3 LHS BOTTOM BACK SECONDARY CAVITY oh LOW VOLTAGE TRANSFORMER 240 N FULL/HALF RL7 11 4 SW2 LHS TOP FRONT PRIMARY 36 RL6 MAINS SWITCH 35 HEATER 34 RL5 13 3 2 XE VERSION USE CN13 1 EE VERSION USE BRIDGE AND CN11
NEUT LIVE LIVE 2 EARTH Or 2 Ph 1 Ph 400 Series Ovens 32Z3769 Issue 1 U(2) FUSE 1 L(1) FILTER N(3) U(4) N(3) L(1) FUSE 2 FILTER U(4) U(2) 2 14 RL6 34 35 HEATER MAINS SWITCH 33 RL5 N DOOR OPEN POSITION SW3 240 SW2 LOW VOLTAGE TRANSFORMER 13 19 30 RHS TOP MOTOR SWITCH MAG COOL FAN 36 28 18 1 RL1 SOFT 2 HOT AIR FAN 1 RESISTOR 270 OHMS CAVITY OVERHEAT SWITCH 29 JP1 MAGNETRON CUT-OUT 64 3 HEATER ELEMENT 20 RL2 SOFT START 470 R GOLD MICRO -WAVE JP3 T CAVIT
400 Series Ovens 32Z3769 Issue 1 2 COOKING 2 M POWER 2 RESISTOR 270 OHM TOP RIGHT NEUTRAL LIVE NEUTRAL LIVE RETURN NEUTRAL CAVITY OVERHEAT SWITCH MAINS SWITCH 1 NEUTRAL LIVE NEUTRAL MOTOR SWITCH TIMER LIVE 12 7 13 5 8 19 14 10 1 2 3 15 3 6 17 18 16 RETURN RL4 2 9 25 24 22 1 20 21 29 30 RL6 HALF 28 RL5 HEAT EARTH RL3 FULL RL2 SOFT 1 2 26 J2 CAVITY TEMP 80mm AXIAL FAN 11 START OPTO RL1 START LIVE J1 DOOR VR2 1 2 3 22 VR1 1 2 3 LIVE NEUTRAL 27 4
NEUT LIVE LIVE 2 EARTH Or 2 Ph 1 Ph 400 Series Ovens 32Z3769 Issue 1 U(2) 10 AMP FUSE 1 L(1) FILTER N(3) U(4) N(3) L(1) FUSE 2 13 AMP FILTER U(4) U(2) 2 14 MAINS SWITCH RL6 34 35 HEATER 33 33A RL5 N SW3 19 30 36 T/TABLE MOTOR RHS TOP MOTOR SWITCH LHS TOP FRONT PRIMARY MAG COOL FAN DOOR OPEN POSITION SW2 240 LOW VOLTAGE TRANSFORMER 13 28 18 1 SOFT RL1 2 HOT AIR FAN 1 RESISTOR 270 OHMS CAVITY OVERHEAT SWITCH 29 JP1 MAGNETRON CUT-OUT 64 3 HEATER ELEMENT 20
