Merrychef Mealstream 500 Service manual

SERVICE
MANUAL
Part No. 32Z3311 Issue No. 8
For all Mealstream 401 models manufactured from January 2001
SERVICE MANUAL
Mealstream 401
CAUTION MICROWAVE EMISSIONS
DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE
GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY
Mealstream 401Ovens 32Z3311 Issue 8
Page 1
Table of Contents
Safety Code ...........................................................................3
Product Specifications ...........................................................4
Principles of Operation ..........................................................5
Installation Instructions ...................................................... 6-7
Error Codes and Diagnostics.................................................8
Main Features........................................................................9
Electronic Controls ..............................................................10
Manual Controls ..................................................................11
Power Output Testing to EN 60335-2-90 ............................12
Power Output Testing ..........................................................13
Power Transformer Test ......................................................13
High Voltage Capacitor Test................................................14
High Voltage Rectifier Test ..................................................14
Magnetron Test ...................................................................14
Door Interlock Operation .....................................................15
Error Light Operation ..........................................................15
Casework .............................................................................16
Door Mechanism .................................................................17
Oven Cavity Components & Hot Air System .......................18
Oven Door Assembly...........................................................19
Magnetron & Door Interlock Components ...........................20
Magnetron & Door Interlock Components ...........................21
Major Electrical Components...............................................22
Input Wiring, Filters and Fuses ............................................23
Input Wiring, Filters and Fuses ............................................24
HT Components ..................................................................25
HT & Principal components: RMC1003__XX5/XX52 ..........26
Electronic Control Panel Assembly .....................................27
Manual Controls Panel Assembly........................................28
Membrane Panel Circuit ......................................................29
Complete Spare Part Listing.......................................... 30-31
Circuit Diagrams ............................................................ 32-34
Appendix 1 MenuKey Download Procedure ........................35
Appendix 2 Cleaning Procedure ..........................................36
Manual corrections and modifications .................................37
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
Mealstream 401Ovens 32Z3311 Issue 8
Page 2
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 401 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 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
MΩ Resistor
Before 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.
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 on a Mealstream 401 oven, or before reconnecting the appliance to the
mains supply for testing, check all of the following points:
•
•
•
•
•
•
•
•
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.
Before 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 11 & 12 ).
Microwave emission is below permissible limit - 5 mW/cm² (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 32Z3311 Issue 8
Page 3
Product specifications
ELECTRONIC CONTROLS
Model Number: RMC1003 + Voltage + Frequency + Current + Controls + Phase
For example: RMC100345XE52
Model Mealstream 401, 230-240V, 50Hz, 30A, Series 5 Controls, Twin Phase
Model prefix
RMC1003
Voltage
2 = 220-230V a.c.
4 = 230-240V a.c
Frequency
5 = 50 Hz
6 = 60 Hz
Current, Output, Heater
Control Supply
Type
Phase
EE = 13A 700W
1500W
XE = 30A 700W
3000W
5=
Series 5
controls
XX = 30A 1000W
3000W
2=
Twin
Phase
MANUAL CONTROLS
Model Number:
Model prefix
RMC1003
RMC1003 + Voltage + Frequency + Current
Voltage
Frequency
2 = 220-230V a.c.
4 = 230-240V a.c.
5 = 50 Hz
6 = 60 Hz
Power
Requirements
Current
CD2 = 13amp
XD2 = 30amp
See RATING PLATE on rear of oven
Power Output
Microwave 100%
Convection
Combination
700W (IEC 705)
3000W
700W + 1500W ( EE )
700W + 3000W ( XE )
1000W + 3000W ( XX5 )
External
Dimensions
Height
Width
Depth
530 mm (Plus 150 mm minimum clearance above)
550 mm (Plus 50 mm minimum clearance each side)
575 mm (Plus 50 mm clearance behind)
Internal
Dimensions
Height
Width
Depth
Turntable
Capacity
315 mm
330 mm
330 mm
300 mm Diameter
34.3 litres
Weight
Nett
Gross packed
All models except XX5 45kg,
All models except XX5 58kg,
Construction
Cavity
Casework
Vitreous Enamel Coated Steel
304 Stainless Steel
Anodised Aluminium Extrusions
Settings
Microwave
Temperature
Timer
100%,75%,50%,25%, Convection only
Off, 175°C, 200°C, 225°C, 250°C, 275°C
Up to 30 minutes
XX5 55kg
XX5 68kg
Up to 3 cooking stages of up to 30 minutes each
(Programmed)
Mealstream 401Ovens 32Z3311 Issue 8
Page 4
Principles of operation
Mealstream 401Ovens 32Z3311 Issue 8
Page 5
Installation instructions
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 50mm clearance at the sides and rear of the
oven, and at least 150mm above. Air intake temperature should not exceed 35°C.
Excessive temperature will lead to reduced operating duty cycle or premature ageing of
internal components.
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 401Ovens 32Z3311 Issue 8
Page 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
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.
Establishments with standard ( Type ‘B’ ) 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__EE5, RMC1003__CD2
The power outlet used must be individually fused. It
is essential that the socket is properly installed and
earthed. It should be fed from a circuit which is
suitable for high power electrical appliances and it is
important that this circuit is not overloaded.
Where an approved and fitted moulded plug is
supplied we strongly recommend that this plug is
never removed.
However certain establishments may require a
different plug to be fitted. In this case, the wiring
instructions shown should be observed.
Diagram 1
Models RMC1003__XE5, RMC1003__XD, RMC1003__XX5
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
Models RMC1003__XE52, RMC1003__XX52
The Mealstream 401 oven Twin Phase models
should be connected as shown in Diagram 2.
The Circuit Breaker should be rated at 45A (TypeC).
Simplified loading Diagram
Mealstream 401Ovens 32Z3311 Issue 8
Diagram 2
Page 7
Error codes and diagnostics
The Mealstream EC401 will identify some of the most common problems by flashing an error
message code in the time display window.
Error Message
Possible Cause
Service
1
Door not fully shut
Close door fully.
2
Possible electrical fault
Check Microswitch Door Circuit
Check Microswitch Connection to PCB
Check Ribbon Cable
Check Relay PCB & Logic PCB
1
2
3
4
No time has been set
Invalid time has been set
Invalid program has been set
Number pad failure
5
Memory Failure running a
Program
Set a time
Set a valid time
Use call-back to check program
(Menukey: no key downloaded)
Membrane key short circuit
Re-Program Pad,
if fault repeats replace Logic PCB
1
Oven not heating up
Check heater fuse
2
Possible Heater circuit fault
Confirm operation of heater, overheat
stat and heater circuit
1
Oven Cavity overheating
Check cavity sensor
Confirm heater relay is operating
1
Oven is not at correct
Allow oven to reach correct
temperature to start program Programmed temperature
Operator Error !!
1
Magnetron overheating
Check that magnetron cooling fan is
working correctly
Check air filters
Check location and air inlet temperature
Note : this will lead to condition shown
below
1
Magnetron has overheated
but has now recovered
Internal diagnostic fault
Check that magnetron cooling fan and
turntable are working correctly
Check installation, air inlet temperature
and air filters
Oven control area is
overheating
Check air filters.
Check axial fan
Check installation for hot air intake
2
1
MenuKey removed before the Switch oven off and begin the MenuKey
download is complete
download again
or the process has been
interrupted
Mealstream 401Ovens 32Z3311 Issue 8
Page 8
Main features
a
b
d
c
e
p
g
f
h
q
n
i
b
l
rear view of Oven
k
m
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 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.
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.
f 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.
h 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.
i AIR INLETS
Additional air inlets are situated along the lower
edge of the left-hand side panel, and must not be
obstructed.
j RATING PLATE
The rating plate is situated on the rear of the
oven, and states the Model, Serial Number,
Electrical Ratings and Manufacturers Tel no.
k 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.
l ON/OFF SWITCH
This is used to turn the oven On or Off.
IT DOES NOT ISOLATE INTERNAL WIRING
FROM THE ELECTRICAL SUPPLY.
m FEET
These feet are fitted to ensure adequate airflow
under the oven. They must not be removed.
n ELECTRICAL SUPPLY LEAD
p AIR FILTER
Main intake for cooling air for internal
components. Must be clear of obstructions.
q MenuKey
Mealstream 401Ovens 32Z3311 Issue 8
Page 9
Electronic controls: Mealstream EC401
a
Stage LED's
b
Service Indicator
a
c
Air Filter Block Indicator
b
d
Operator error indicator
c
e
Program Display
d
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
g
MenuKey socket
i
0
175
200
225
250
275
1
2
3
4
5
6
7
8
9
P
0
C
25%
50%
h
j
k
75%
l
m
100%
Starbucks model
Mealstream 401Ovens 32Z3311 Issue 8
Page 10
Manual controls: Mealstream RD401
a
b
a
Temperature Amber Neon
b
Temperature Control
c
Microwave Power Control
d
Timer
e
Start Pushbutton
f
Cook cycle Red Neon
g
Power Amber Neon
h
On/Off switch
c
d
e
f
g
h
Mealstream 401Ovens 32Z3311 Issue 8
Page 11
Procedure A - Power Output Test
In accordance with 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°C.
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
- take 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 height 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:
P=
4.187 MW (T2-T1) + 0.55 MC (T2-T0)
t
where
P
MW
MC
T0
T1
T2
t
is the microwave power output, in watts;
is the mass of the water, in grams;
is the mass of the container, in grams;
is the ambient temperature, in °C;
is the initial temperature of the water, in °C;
is the final temperature of the water, in °C;
is the heating time in seconds, excluding the magnetron filament heat-up time.
Mealstream 401Ovens 32Z3311 Issue 8
Page 12
Procedure B - Simplified Power Output Test
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
Measure 1 litre of cold water into the tray using the measuring jug.
Measure the water temperature, and record it as T[s].
Place the tray on the turntable in the oven and close the door.
Turn the oven on.
Set the timer to 1:02. ( For Manual controls use a stopwatch set to 1 minute 2 seconds )
Press the “100%” power pad.
When the oven bleeps, open the door and remove the tray.
Stir the water thoroughly, and measure its temperature. Record this as T[e].
Calculation:
1
2
T[r] = T[e] - T[s].
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. Isolate the oven before testing.
2
3
4
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 continuity of the windings. Results should be as follows:
a
Mains winding between tags
Approx. 1.3 Ω
b
High Voltage winding
Approx. 82 Ω
c
Filament winding
between terminals
Less than 1 Ω
5
Using a Megger, test the insulation resistance between:
Primary winding and chassis
Pass if over 10 MΩ
Filament winding and chassis
Pass if over 10 MΩ
c
b
a
One end of the High Voltage winding is connected to the
chassis, so this is not tested.
Mealstream 401Ovens 32Z3311 Issue 8
Page 13
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 .
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. Using a D.M.M., check for continuity between the terminals &
compare results with table.
Between Terminals
Pass if approximately 10 MΩ
Between Terminals and Case
Pass if open circuit
5. Using a Megger, test the insulation resistance between the
terminals and the case.
Between Terminals and Case
Pass if over 100 MΩ
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.
Open Circuit both ways
FAIL
Conducts one way only
PASS
Short Circuit both ways
FAIL
Conducts one way, leaks the other
FAIL
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 continuity 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 401Ovens 32Z3311 Issue 8
Page 14
Door interlock operation
The door on the Mealstream 401 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:
56
Door Interlock Arrangement
Top RH
57
L
Power In
Bottom Inner
Top LH 55
Bottom Outer
58
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
emission 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 “E: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 32Z3311 Issue 8
Page 15
Principal components: casework
105
96
104
105A
MC3134
9
Handle Hanger
RCK6319
RMC6773
10
Rubber Foot
RMC6104
MC3120X01
11
Front Lower Panel
MC3047
Top Plate
RMC6759E
12
Lower Trim
MC3122
5
Exhaust Gallery
RMC73372
96
PCB 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 Trim RH
MC31212
1
Side Panel (L/H)
2
Ferrit
3
Upper Trim
4
Mealstream 401Ovens 32Z3311 Issue 8
Page 16
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
21
Microswitch Guide
40H0076
22
Solid Door Assy Black
11H0071
22
Solid Door Assy Silver
11H0031
Mealstream 401Ovens 32Z3311 Issue 8
MC3040
MC30121X02
MC3068X01
MC30122X01
Page 17
Oven cavity components and hot air system
23
Turntable Disc
RMC7340X01
31
Gearbox
24
Baffle Plate Bolt
25
Baffle Plate
26
Fan Fixing Cap
27
MC3216
CP30326
32
Shaft
MC3018
33
Cooling Fan
RCK7617
34
Motor Bracket
Fan
MC3111
35
Cushion Rubber
RCK8273
28
Partition Plate
11H0007
36
Motor Fixing Screw
CP30310
29
Cavity Sealing Glass
RMC7043
37
Hot Air Motor
30
Oven Body
RMC7391X01
RMC7310
RMC7307X01
MC3110
MC3013
Mealstream 401Ovens 32Z3311 Issue 8
Page 18
Oven door assembly
Solid door assembly, Silver 11H0031
Solid door assembly, Black 11H0071
22
Solid Door Assy. Silver
11H0031
22
Solid Door Assy Black
11H0071
38
Door Handle Silver
RBR1285048
38
Door Handle Black
RBR12852
39
Door Frame (A) Black
MC30503
40
Door Cover Outer Silver
40H0080
40
Door Cover Outer Black
40H0082
41
Insulation Panel
40H0081
42
Door Reinforcement
43
Door Frame (B)
MC3055
44
Insulation Wrap
32Z0001
46
Door Base Silver
47
Door Cover
MC3064
48
Plate - Door Switch
MC3056
52
Packing (B)
MC3065
53
Door Rear Plate
Mealstream 401Ovens 32Z3311 Issue 8
RMC70722
MC3031KX04
MC3066X01
Page 19
Magnetron and door interlock components
Model RMC1003__EE5
Model RMC1003__XE5
54 Door Switch Bracket
40H0023
62 Inlet Duct
55
56
57
58
30Z0240
30Z0240
30Z0240
30Z0240
63 Magnetron
30Z0264
64 Magnetron Cut-out
30Z0088
59 Microswitch Insulator
31Z0115
66 Blower Assembly
MC3141
60 Outlet Duct
MC3037
67 M3 x 25 Pan Head Pozi
31Z3093
61 Foam Tape
31Z0042
68 M3 x 30 Pan Head Pozi
31Z3118
Primary Microswitch
Low Voltage Microswitch
Secondary Microswitch
Monitor Microswitch
Mealstream 401Ovens 32Z3311 Issue 8
65 Switch Bracket
RMC7193X01
RMC7101X01
Page 20
Magnetron and door interlock components
Model RMC1003__XX5
Model RMC1003__XX52
129
133
128
128
54 Door Switch Bracket
40H0023
64 Magnetron Cut-out
55 Primary Microswitch
56 Low Voltage Microswitch
57 Secondary Microswitch
30Z0240
30Z0240
30Z0240
65 Switch Bracket
59 Microswitch Insulator
31Z0115
128 Cooling Fan 220/240V
30Z1128
60 Outlet Duct
MC3037
128 Cooling
30Z1190
61 Foam Tape
31Z0042
129 Turntable Motor
63 Magnetron
30Z0264
Mealstream 401Ovens 32Z3311 Issue 8
30Z0088
RMC7101X01
67 M3 x 25 Pan Head Pozi
31Z3093
68 M3 x 30 Pan Head Pozi
31Z3118
133 Inlet Duct
Fan
220V
RMC5055EX
40H0176
Page 21
Major electrical components
*Not
RMC1003__XX5/XX52
See Page 23
64 Magnetron Overheat Switch
30Z0088
74 Temperature Sensor
50E123
69 Cavity Overheat Switch
30Z1031
75 HV Diode Assembly
11H0010
70 Bridge Rectifier (__EE only)
71 No. 8 Screw
341520
31Z3107
72 M5 Screw
101825
76 HT Capacitor 1.1µ
(50Hz)
30Z1077
76 HT Capacitor 0.88µ (50Hz)
30Z1075
76 HT Capacitor 0.6µ
(60Hz)
30Z0385
30Z0377
73 220V Heating Element
40H0077
76 HT Capacitor 0.74µ (60Hz)
73 240V Heating Element
40H0009
117 Axial Fan, 80mm
73 240V Heating Element
40H0009
Mealstream 401Ovens 32Z3311 Issue 8
310010
Page 22
Input wiring, filters and fuses
Model RMC1003__XE5, XD
Model RMC1003__EE5, CD2
Green / Yellow
Green / Yellow
Blue
Blue
Brown
Brown
111
112
112a
115
111
111 Mains Input Block
31Z0328
112 Cable Gland
31Z1070
112A Cable Gland Nut
113 Input Cable Assembly
115 XE5 Input Cable Assembly
116 Strain Relief Grommet
116
113
31Z1082
31Z0220
302030
31Z1036
82
78
79
81
77
80
79
81
77 Microwave Mains Filter 16A
30Z0997
78 Heater Mains Filter 16A
30Z0997
79 Fuse Cover
20Z1080
80 Fuse 10A HRC
30Z0217
81 Fuse Holder 1”
30Z0231
82 Fuse 13A Anti-surge
30Z0168
Mealstream 401Ovens 32Z3311 Issue 8
Page 23
Input wiring details: Model RMC1003__XX5, XX52
Green / Yellow
Green / Yellow
Blue
Blue
Brown
L2
111
112
112a
L1
115
111
111 Mains Input Block
31Z0328
112 Cable Gland
31Z1070
112A Cable Gland Nut
113 Input Cable Assembly
31Z1082
31Z0220
115 XE5 Input Cable Assembly
116 Strain Relief Grommet
302030
31Z1036
78
77
79
82
81
80
79
81
77 Microwave Mains Filter 16A
30Z0997
78 Heater Mains Filter 16A
30Z0997
79 Fuse Cover
20Z1080
80 Fuse 10A HRC
30Z0217
81 Fuse Holder 1”
30Z0231
82 Fuse 13A Anti-surge
30Z0168
Mealstream 401Ovens 32Z3311 Issue 8
Page 24
HT Components: RMC1003__EE5/ XE5
75 HV Diode Assembly
76 HT Capacitor 1.1µ
11H0010
(50Hz)
30Z1077
76 HT Capacitor 0.88µ (50Hz)
30Z1075
76 HT Capacitor 0.6µ
(60Hz)
30Z0385
76 HT Capacitor 0.74µ (60Hz)
30Z0377
88 HT Transformer Top Bracket
MC3127
89 HV Lead Assembly, Ferrit
11H0025
90 HT Transformer 240V
30Z1183
90 HT Transformer 220V
30Z1018
91 HT Transformer Bottom Bracket
40H0070
92 Capacitor Band
RMC7215
93 Filter Bracket
40H0065
94 HT Transformer Support Bracket
MC3024
Mealstream 401Ovens 32Z3311 Issue 8
Page 25
HT & principle components: Models RMC1003__XX5, RMC1003__XX52
Right
side
102
130
132
128
90
90
76
76
76*
HT Capacitor 0.88µF (50Hz)
30Z1075
76*
HT Capacitor 0.6µF
(60Hz)
30Z0385
76*
HT Capacitor 0.74µF (60Hz)
30Z0377
90
Transformer 220V 50/ 60Hz
30Z1018
90
Transformer 220V 60Hz
30Z1192
90
Transformer 240V 50/ 60Hz
30Z1183
90
Transformer 240V 60Hz
30Z1191
102 Resistor 470R 50W (Gold)
30Z0283
128 Cooling Fan 220/240V 50Hz
30Z1128
128 Cooling Fan 220V 60Hz
30Z1190
130 Diode Board
11H0058
132 Heater Relay
30Z0986
*Note: 50Hz models use 2x 0.88µF Capacitors
60Hz models use 1x 0.6µF and 1x 0.74µF Capacitors
Mealstream 401Ovens 32Z3311 Issue 8
Page 26
Electronic control panel assembly
100
110
102
98
101
99
107
95
108
107
103
0
175
200
225
250
275
1
2
3
4
5
6
7
8
9
P
0
C
25%
50%
110
75%
100%
107
100
97
109
Membrane Panel
Menukey
(Blue)
Model
97
131
95
Membrane Assy
97
On/Off Switch
98
Logic Assy.
99
Support Shield
See Table
30Z0503
See Table
Membrane Panel
Starbucks
(Red/ Grey)
Membrane Assy Logic PCB
EE5, XE5, XX5
11H0060
11C0285
XX5 Starbucks
11H0024
11C0285
EE5, XE5, XX5
Menukey
11H0067
11C0066
XX5 Locare
11H0073
11C0066
103 Relay Assy.
11C0286
107 PCB Stand-off
31Z7010
108 15 Way Ribbon Connector
11Z0298
40H0075
109 Single 0.25” Blade Tag
100 M3 x 5 Screw
31Z3106
110 M3 Nylon Support
31Z0206
101 No. 4 x 3/8” Screw
31Z3112
131 Menukey Assembly
10C0148
102 470R 50W Resistor
30Z0283
Mealstream 401Ovens 32Z3311 Issue 8
309610
Page 27
Manual control panel assembly
105A
123
124A
121
124B
124C
124D
122
125
105
126
97
123
97
On/Off Switch
30Z0503
104
PCB Retainer RH
40H0084
105
Side Trim LH
MC31211
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
11C0173
124E Control Knob Assy Blue
11C0406
Pushbutton (Start)
126
Red Neon
127
Potentiometer
Mealstream 401Ovens 32Z3311 Issue 8
104
127
313030
124E Control Knob Assy Black/Red
125
106
31Z0349
316030
Control Board not
shown for clarity
40C0892
Page 28
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.
Mealstream 401Ovens 32Z3311 Issue 8
Page 29
Part number identification chart 1
1
SIDE PANEL (L/H)
MC3134
41
INSULATION PANEL
2
FERRITE
3
RMC6773
42
DOOR REINFORCEMENT
UPPER TRIM
MC3120X01
43
DOOR FRAME (B)
MC3055
4
TOP PLATE
RMC6759E
44
INSULATION WRAP
32Z0001
5
EXHAUST GALLERY
RMC73372
46
DOOR BASE SILVER
MC3031KX04
6
REAR PANEL
MC3129
47
DOOR COVER
MC3064
7
GREASE FILTER
MC3155
48
PLATE - DOOR SWITCH
MC3056
8
SIDE PANEL (R/H)
MC3133
52
PACKING (B)
MC3065
9
HANDLE HANGER
RCK6319
53
DOOR REAR PLATE
10
RUBBER FOOT
RMC6104
54
DOOR SWITCH BRACKET
11
FRONT LOWER PANEL
MC3047
12
LOWER TRIM
MC3122
13
DOOR STAY (R/H)
MC3040
14
HINGE BODY
55
56
57
58
PRIMARY MICROSWITCH
LOW VOLTAGE MICROSWITCH
SECONDARY MICROSWITCH
MONITOR MICROSWITCH
15
HOOK (A)
RMC66171
59
MICROSWITCH INSULATOR
31Z0115
16
HOOK (B)
RMC66172
60
OUTLET DUCT
MC3037
17
DOOR SPRING (B)
MC3068X01
61
FOAM TAPE
31Z0042
18
HINGE BODY (L/H)
MC30122X01
62
INLET DUCT
RMC7193X01
19
DOOR SPRING (A)
MC3067
63
MAGNETRON
30Z0264
20
DOOR STAY (L/H)
MC3046
64
MAGNETRON CUT-OUT
30Z0088
21
MICROSWITCH GUIDE
40H0076
65
SWITCH BRACKET
22
SOLID DOOR ASSY SILVER
11H0031
66
BLOWER ASSEMBLY
22
SOLID DOOR ASSY BLACK
11H0071
23
TURNTABLE DISC
24
BAFFLE PLATE BOLT
CP30326
25
BAFFLE PLATE
MC3018
26
FAN FIXING CAP
RCK7617
27
FAN
28
MC30121X02
40H0081
RMC70722
MC3066X01
40H0023
30Z0240
RMC7101X01
MC3141
(NOT RMC1003__XX5, XX52)
67
M3 X 25 PAN HEAD POZI
31Z3093
68
M3 X 30 PAN HEAD POZI
31Z3118
69
CAVITY OVERHEAT SWITCH
30Z1031
70
BRIDGE RECTIFIER (EE ONLY)
MC3111
71
N0. 8 SCREW
PARTITION PLATE
11H0007
72
M5 SCREW
29
CAVITY SEALING GLASS
RMC7043
73
73
240V HEATING ELEMENT
220V HEATING ELEMENT
40H0009
40H0077
30
OVEN BODY
MC3013
74
TEMPERATURE SENSOR
50E123
31
GEARBOX
MC3216
75
HV DIODE ASSEMBLY
11H0010
32
SHAFT
76
HT Capacitor 1.1µ
(50Hz)
30Z1077
33
COOLING FAN
76
HT Capacitor 0.88µ (50Hz)
30Z1075
34
MOTOR BRACKET
RMC7307X01
76
HT Capacitor 0.6µ
(60Hz)
30Z0385
35
CUSHION RUBBER
RCK8273
76
HT Capacitor 0.74µ (60Hz)
30Z0377
36
MOTOR FIXING SCREW
CP30310
37
HOT AIR MOTOR
MC3110
38
DOOR HANDLE BLACK
RBR12852
38
DOOR HANDLE SILVER
RBR1285048
39
DOOR FRAME (A) BLACK
MC30503
40
DOOR OUTER BLACK
40H0080
40
DOOR OUTER SILVER
40H0082
RMC7340X01
RMC7391X01
RMC7310
Mealstream 401Ovens 32Z3311 Issue 8
341520
31Z3107
101825
Page 30
Part number identification chart 2
77
78
M’WAVE MAINS FILTER 16A
HEATER MAINS FILTER 16A
30Z0997
30Z0997
117
80mm Axial Fan
310010
121
PCB Assembly
11H0027
79
FUSE COVER
20Z1080
122
Timer
30Z0991
80
FUSE 10A HRC
30Z0217
123
Neon Amber
316031
81
FUSE HOLDER 1”
30Z0231
124A
Control Knob Black
313020
82
FUSE 13A ANTI-SURGE
30Z0168
124B
Control Knob Skirt Red
313160
88
HT TRANSFORMER TOP
MC3127
124B
Control Knob Skirt Blue
31Z1216
89
HV LEAD ASSEMBLY
11H0025
124C
Control Knob Cap Red
313220
90
Transformer 220V 50/ 60Hz
30Z1018
124C
Control Knob Cap Blue
31Z1217
90
Transformer 220V 60Hz
30Z1192
124D
Control Knob Shaft Adapter
90
Transformer 240V 50/ 60Hz
30Z1183
124E
Control Knob Assy Black/Red
11C0173
90
Transformer 240V 60Hz
30Z1191
124E
Control Knob Assy Blue
11C0406
91
HT TRANSFORMER BOTTOM
31Z0349
92
313030
40H0070
125
Pushbutton (Start)
CAPACITOR BAND
RMC7215
126
Neon Red
93
FILTER BRACKET
40H0065
127
Potentiometer
40C0892
94
HT TRANSFORMER SUPPORT
BRACKET
MC3024
128
Cooling Fan 220/240V 50Hz
30Z1128
95
MEMBRANE ASSEMBLY
128
Cooling Fan 220V 60Hz
30Z1190
96
PCB RETAINER LH
40H0083
129
Turntable Motor
97
ON/OFF SWITCH
30Z0503
130
Diode Board
11H0058
98
LOGIC ASSY.
131
Menukey Assembly
10C0148
99
SUPPORT SHIELD
40H0075
132
Heater Relay
30Z0986
100
M3 X 5 SCREW
31Z3106
133
Inlet Duct
40H0176
101
NO. 4 X 3/8” SCREW
31Z3112
102
470R 50W GOLD RESISTOR
30Z0283
103
RELAY ASSY.
11C0286
95
RMC1003__EE5, XE5, XX5_, Haari
11H0060
104
PCB RETAINER RH
40H0084
95
RMC1003__XX5 Starbucks
11H0024
105
SIDE TRIM LH
MC31211
95
11H0067
105A SIDE TRIM RH
MC31212
RMC1003__EE5, XE5, XX5_
Menukey
95
RMC1003__XX5 Locare
11H0073
SEE TABLE
SEE TABLE
106
M4 FLAT WASHER
31Z5004
107
PCB STAND-OFF
31Z7010
108
15 WAY RIBBON CONNECTOR
11Z0298
109
SINGLE 0.25” CONNECTOR
110
M3 NYLON SUPPORT
31Z0206
111
MAINS INPUT BLOCK
31Z0328
112
CABLE GLAND
31Z1070
CABLE GLAND NUT
31Z1082
113
INPUT CABLE ASSEMBLY
31Z0220
115
XE5 INPUT CABLE ASSEMBLY
116
STRAIN RELIEF GROMMET
112A
309610
Model
Model
316030
RMC5055EX
Membrane
Assembly
Logic PCB
98
RMC1003__EE5, XE5, XX5_, Haari
11C0285
98
RMC1003__XX5 Starbucks
11C0285
98
RMC1003__EE5, XE5, XX5_
Menukey
11C0066
98
RMC1003__XX5 Locaire
11C0066
302030
31Z1036
Mealstream 401Ovens 32Z3311 Issue 8
Page 31
Circuit diagram: RMC 1003__5 EE & RMC 1003__XE
Mealstream 401Ovens 32Z3311 Issue 8
Page 32
Circuit diagram: RMC 1003__XX5 (Single Phase)
Mealstream 401Ovens 32Z3311 Issue 8
Page 33
Circuit diagram: RMC 1003__XX52 (Twin Phase)
Mealstream 401Ovens 32Z3311 Issue 8
Page 34
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.
The oven will now go through the
program download sequence by
displaying the following:
The Key Code
example: Key C02
The number of programs and each
program number on the key.
example: 27 Programs
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.
When the display shows 00:00
remove the key and close the cover.
The oven is now ready to use with the
new programs.
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 401Ovens 32Z3311 Issue 8
Page 35
APPENDIX 2: Cleaning Procedure
For the oven to operate at peak efficiency, the cavity, door and air filters must be kept clean.
A daily cleaning routine will ensure that 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.
• 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.
1.
2.
Remove the air filter from the rear panel of the oven by
sliding the filter up and out of the slots.
Wash in clean, warm soapy water, rinse and pat dry. Slide
back into position through slots.
Cleaning the oven cavity and door
1
2.
3.
Remove trays, racks and the rear baffle plate ( undo the four
wing nuts ), turntable and turntable disc. Clean using noncaustic oven cleaner.
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. Leave for the recommended time. Wash off using a clean
cloth and plenty of clean, warm water. Dry using a fresh, clean
DO NOT USE THE OVEN
WITHOUT A CLEAN AIR
FILTER IN POSITION
cloth.
4.
5.
Wipe hinges with a clean, damp cloth.
DO NOT apply lubricating oil.
Wipe door seals carefully with a clean damp cloth. Examine for
6.
signs of wear or damage.
Replace baffle plates and tighten wing 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
1.
2.
3.
Switch on oven with microwave power only (without heat).
Place a container of water (1.5 litres) into the centre of the oven cavity.
Set microwave power to 100%.
4.
Set timer to 30 minutes and press start button.
At end of steam cycle, wipe out cavity with a clean cloth.
Mealstream 401Ovens 32Z3311 Issue 8
Page 36
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.
Name
Address
Page on which error occurs (if applicable) - Mealstream 401 Series
Description of error
Suggestion for improvement to manual
Please return this form to:
Quality Department
Merrychef Ltd
Station Road West
Ash Vale
Aldershot
Hampshire
GU12 5XA
Or Fax it on:
+44 (0) 1252 371007
E-mail
quality@merrychef.com
Mealstream 401Ovens 32Z3311 Issue 8
Page 37