Merrychef 402s Service & Parts Manual

Merrychef

Version 3.0

Version 2.0

402s

S E R V I C E & P A R T S M A N U A L

This manual covers UK/EC models manufactured from:

Version 2.0 Serial No. 000745 –001199

Version 3.0 Serial No. 001200 onwards

ISSUE 5

23.09.2008

CAUTION MICROWAVE EMISSIONS

DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE

GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY

402s Ovens Part. N o.

32Z3539 Issue 5

1

TABLE OF CONTENTS

Safety code..............................................................................3

Main features control panel Version 2.0 ..................................7

Main features control panel Version 3.0 ..................................8

Principal components: Control Box .......................................11

Principal components: Back View .........................................12

Principal components: Power Supply ....................................13

Principal components: Cavity Parts & KFC Accessories ......14

Procedure for Power output measurement............................19

Procedure for door interlock adjustment.......................... 22-24

Hot Air Motor and controller............................................. 25-26

Appendix 1: Temperature Sensor resistance data ................40

Appendix 2: MenuKey download procedure V2.0 .................41

MenuKey download procedure V3.0 .................42

Appendix 3: Cool down & Cleaning Procedure ............... 43-45

Appendix 4: Recommended Spares List ...............................46

Appendix 5: PCB connection Points................................ 47-48

Appendix 6: Firmware revision guide............................... 49-54

Appendix 7: Electrical Installation Guide ...............................55

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: [email protected] or [email protected]


32Z3539 Issue 5

2

SAFETY CODE

This manual is designed to assist engineers who have been on a recognised product familiarisation and training course run by Merrychef. 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 M

Ω 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.

•

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 the oven, or before reconnecting the appliance to the electrical supply for testing, check all of the following points:

•

All internal electrical connections are correct (see wiring diagram).

•

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 5 mW/cm².

•

The power output of the oven is checked in accordance with the procedure page.

•

Oven has correct 50mm (2 inches) air gap all round and 50mm (2 inches) above.

Air flow should not be restricted.


32Z3539 Issue 5

3

PRODUCT SPECIFICATIONS

Serial Number (Rating Plate):

Month 00/ Year 00/ Production number 00000 e.g 01 08 03349 Oven manufactured January, 2008, production number 03349

Model Number:

402S VVV F P C R TT ZZ

Example 402S2205BK2GMEU

Model No. EC402s

220V, 50Hz, L1 +L2 +N +Earth supply, MenuKey Revision 1, General Market, EU

Supply

Voltage

Freq.

Hz

Phase/Supply

Control

Type

VVV

Voltage (ac)

208 = 208V

220 = 220-230V

240 = 230-240V

F

5 =

50Hz

6 =

60Hz

P

Phase Arrangement

A =

L + N + E (30 Amp)

B =

L1 + L2 + N + E

C =

2 P + Gnd (20 Amps)

D =

2 P + Gnd (30 Amps)

C

K =

Electronic

MenuKey

Type

Country

/Region

R

1

2

3

TT

GM =

General

Market

ZZ

UK =

United

Kingdom

US =

USA

EU =

Europe

Power

Requirement

See Rating Label

Power Output Microwave 100%

Convection

1500watts

3250watts

External

Dimensions

Height

Width

Depth

595mm (23.0 inches)

585mm (23.0 inches)

700mm (27.5 inches)

Weight Nett

Construction Cavity

Casework

90kg ( 198lb.s )

304 Stainless Steel


32Z3539 Issue 5

4

INSTALLATION INSTRUCTIONS

Installation Instructions for Mealstream 402s Ovens

Power Supply Requirements

The Mealstream 402s 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 3mm ( 1/8 inch ) should be fitted.

Earth Bond terminal

An Earth Bond Terminal is provided on the rear panel of the oven for independent Earth (GND) connection.

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 50 mm ( 2 inches ) clearance at the sides and rear of the oven.

Air intake temperature should not exceed 45°C (110°F ) 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 baffle plate.

Stacking the oven ( Maximum one only)

Using stacking kit Part No. SA129

Note:

The minimum recommended clearance required for air flow


32Z3539 Issue 5

5

MAIN FEATURES

a c e

L b

L f d m j i h k k

a On/Off SWITCH

This is used to turn the oven On or Off.

IT DOES NOT ISOLATE INTERNAL WIRING

FROM THE MAINS SUPPLY.

b MenuKey

The MenuKey System automatically changes all the cooking programs with an electronic key and allows program names to be identified.

c OVEN CAVITY

The oven cavity is mainly constructed from stainless steel panels. It must be kept clean.

d GREASE FILTER

The grease filter must be cleaned on a regular basis, and kept free of debris.

e RACK

The cooking rack should be removed daily and cleaned

f HOT AIR FAN

Situated behind the grease filter and circulates the hot air through the cavity.

g RATING PLATE

The rating plate is situated on the rear of the oven, and states the Model, Serial Number,

Electrical Ratings and Manufacturers telephone number.

h 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.

i 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.

j ELECTRICAL SUPPLY CORD

Electrical supply cord is situated on the rear of the oven,

k AIR FILTERS

Main intake for cooling air for internal components. Must be clear of obstructions.

L

IMPINGER PLATES ( Upper & 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


32Z3539 Issue 5

6 g

MAIN FEATURES

Electronic control panel

:

Version 2.0

PREHEAT/ COOL DOWN

FAN SPEED PADS

MAIN DISPLAY

PANEL

START

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 of 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

POWER PADS FUNCTION

PADS

CANCEL

PAD

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 10% steps. ( 0% to 100% )

The default setting is 50% 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

Display Panel error messages

ERROR MAGNETRON 1

ERROR MAGNETRON 2

ERROR MAGNETRON 1 & 2

CAVITY SENSOR ERROR

Magnetron 1 has overheated


Blocked Air filter(s)

Oven located near hot air sources

Oven being used empty

Cooling fan failure

Magnetron failure

Magnetron 1 and 2 have overheated

Cavity temperature exceeds more than 50°C above PREHEAT temperature setting during cook cycle

Indicates combustion ( fire ) in oven cavity

Note: In service operations when

PREHEAT is set to 0°C this message can appear when the oven is operated


32Z3539 Issue 5

7

MAIN FEATURES

Electronic control panel

:

Version 3.0

COOL DOWN

MAIN DISPLAY

PANEL

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

PADS

CANCEL

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 function pads select options shown in the

DISPLAY PANEL.

COOL DOWN PAD

Puts the oven into Cool Down Mode prior to cleaning

Display Panel error messages

Error Message

Magnetron 1 Overheat

Ensure air filters are clean

Allow oven to cool

Magnetron 2 Overheat


Allow oven to cool

Magnetron 1 & 2 Overheat


Allow oven to cool

Magnetron 1 Failure

Magnetron 2 Failure

Magnetron 1 & 2 Failure



Magnetron 1 & 2 have overheated

Blocked air filters

Oven located near hot air source

Oven being used empty

Cooling fan failure

Magnetron failure

Ambient Overheat


Allow oven to cool

Cavity Overheat

Please contact service

Heater Failure

Magnetron 1 no microwave output Check power supply

Magnetron failure

Magnetron 2 no microwave output

Magnetron 1 & 2 no microwave output

Temperature inside casing has exceeded limit

Cavity temperature has exceeded more than 295°C

Cavity has not reached a temperature of 100°C in 10 minutes

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

One or more heater elements have failed and need to be replaced


32Z3539 Issue 5

8

PRINCIPAL COMPONENTS: Right Side

1

5

6

6

7

8

71

4

No. Description

1 Cavity Overheat stat

2 Motor Start Capacitor 2µF ( Blue )

5

8

Stirrer motor Assembly

SW1

Microswitch SW2

7 Door Hinge Assembly RH

Magnetron Cooling Fan

26 HV Capacitor 2500V 1.1µF ( 50HZ models )

26 HV Capacitor 2500V 0.88µF ( 60HZ models )

26A HV Capacitor universal clip

70 Fibre Optic PCB

30Z1024

30Z1298

30Z1340

SA276

SA288

30Z1294

SA202

30Z1295

30Z1242

30Z1251

31Z1261

11M0364

30Z1362

2

3

26

26A

70


32Z3539 Issue 5

9

PRINCIPAL COMPONENTS: Left Side

24

3

25A

25

70

No. Description

3 Filter 16A (Threaded)

9

Microswitch SW4

Door Hinge Assembly LH

25 HV Capacitor 2500V 1.0µF ( 50Hz models )

25 HV Capacitor 2500V 0.88µF ( 60Hz models )

25A HV Capacitor clip

30Z1340

SA276

SA288

30Z1294

SA203

30Z1319

30Z1315

30Z1331

30Z1251

31Z1261

11M0364

5

6

6

9

10

4


32Z3539 Issue 5

10

PRINCIPAL COMPONENTS: Control Box

See

Principal components:

POWER

SUPPLY

11

16

72

17

18

59

No. Description

12 Gold resistor ( 220R )

13 Relay PCB Assembly

14 Ribbon Cable 15way

15 Ribbon Cable 10way MenuKey

16 Logic PCB Assembly Version 2.0

16 Logic PCB Assembly Version 3.0

17 Transformer LT (Low voltage)

59 Sounder

72 Fibre Optic Logic PCB

30Z0217

30Z0235

11K0004

11Z0298

11M0117

11K0002

11K0012

30Z1155

30Z0957

SA257

11K0013

11

12

13

14

15


32Z3539 Issue 5

11

PRINCIPAL COMPONENTS:

Back view

74

22

21

27

No. Description

20

20

Heater Element 220V 650W


22 Magnetron Thermistor Assembly

23

27

27

28

Convection ( Hot Air ) Motor Assembly

Transformer 208/220/240V 50Hz


HT Diode Assy PCB (Fibre Optic)

28A HT Diode Assembly ( Non-optic)

DV0606

DV0607

30Z1349

SA234

SA208

30Z1233

30Z1230

11H0364

11H0010

DV0039

DV0040

20

28

27

28A

73

21

22

23


32Z3539 Issue 5

12

PRINCIPAL COMPONENTS: Power Supply

Electrical Supply: Single Phase

3

29

31

32

11

34

Electrical Supply: Twin phase

2P+N+Earth

29A

29A

N1 L1 L2

No. Description

11 Fuse 10A HRC

19

Cable Gland

Cable Gland Nut

29 Electrical Supply Lead Assembly Single Phase

29A Electrical Supply Lead Assembly Twin Phase

31 Fuse 20A FLM

32 Fuse Holder 30A

34 Fuse Holder 10A


32Z3539 Issue 5

13

30Z1340

30Z0217

31Z0500

31Z0499

SA226

SA225

31Z0447

30Z1177

30Z1178

30Z0231

19

29

30

PRINCIPAL COMPONENTS

Cavity

35

36

36

38

39

40

Stirrer glass

Shown removed

No. Description

35* Grease Filter ( 2 parts )

37* Rack Support ( Not shown )

38 Upper Impinger plate

39 Rack

40 Lower Impinger plate

* Parts 35 & 37 Contact Service Department

KFC Accessories

SA291

SA340

SA339

DV0492

DV0114

SA211

DV0275

SA266

62

63

60

61

65 Chicken Griddle SA133

No. Description

60 Cool-down

61 Oven tray

63 Griddle

65 Chicken Griddle (SA350 + DV0221 + DV0267)


32Z3539 Issue 5

14

32Z4028

MC3175

SA267

DV0221

SA350

SA133

64

5A


External Parts

41

45

42

43

4

52 Door Assembly

46

No. Description

43 Side Panel LH

48

49

Door Choke

Door Seal (wide)

Door seal sealant ( tube )

51 Side Panel RH


32Z3539 Issue 5

15

47

48

49

SA276

DV0187

SA329

DV0091

DV0501

32Z1066

SA331

DV0168

DV0305

31Z0186

DV0037

DV0092

SA111

Control Panel

See page 16

52

51

50

4


Electronic Control Panel Assembly

Version 2.0

55

53

Version 3.0

66

58

53

57

54

54

56

67

68

58

No. Description

53 MenuKey Dust Cover

55

56

57

66

GM Membrane Version 2.0

Front Panel Version 2.0

Display Assembly & Header Version 2.0

GM Membrane Version 3.0

67 Front Panel Version 3.0

68 Display Assembly & Header Version 3.0


32Z3539 Issue 5

16

DV0052

30Z1318

DV0055

DV0036

30Z1299

11K0005

DV0254

DV0249

30Z1324

Part number identification chart 1

21

22

23

24

25

25

25A

26

26A

27

27

28

29

29A

Ref. No. Description

1 Cavity High limit Stat

2 Motor Start Capacitor 2µF ( Blue )

3 Filter 16A

7

8

9

10

4

5

5A

6

11

12

13

14

15

16

16

17

18

19

20

Air filter

Stirrer motor Assembly

Stirrer (inside cavity)

Microswitch SW1, SW2, SW3, SW4

Door Hinge Assembly RH

Magnetron Cooling Fan

Door Hinge Assembly LH

Motor Controller

Fuse 10A HRC

Gold resistor ( 220R )

Relay PCB Assembly

Ribbon Cable 15way

Ribbon Cable 10way MenuKey

Logic PCB Version 2.0/ 2.5

Logic PCB Assembly Version 3.0

Transformer LT (Low voltage)

Fuse 1A

Cable Gland

Cable Gland Nut



Magnetron (Toshiba)

Magnetron Thermistor Assembly

Convection ( Hot Air ) Motor Assembly

Thermistor Cavity

HV Capacitor 2500V 1.0µF ( 50Hz Models)

HV Capacitor 2500V 0.88µF ( 60Hz Models )

HV Capacitor clip universal

HV Capacitor 2500V 1.1µF (50Hz Models)

HV Capacitor clip universal



HT Diode Assy

Electrical Supply Lead Assembly

Electrical Supply Lead Assembly Twin Phase

30

31

Terminal Block

Fuse 20A FLM


32Z3539 Issue 5

17

Part No.

30Z1024

30Z1298

30Z1340

SA276

SA288

SA213

30Z1294

SA202

30Z1295

SA203

30Z1319

30Z0217

30Z0235

11K0004

11Z0298

11M0117

11K0002

11K0012

30Z1155

30Z0957

31Z0500

31Z0499

DV0606

DV0607

30Z1349

SA234

SA208

30Z1315

30Z1331

30Z1251

31Z1261

30Z1242

31Z1261

30Z1233

30Z1230

11H0010

SA226

SA225

31Z0447

30Z1177

Part number identification chart 2

Part No. Ref.

No.

Description

32 Fuse Holder 30A

34 Fuse Holder 10A

35 Grease Filter ( 2 parts )

36 Stirrer Glass

37 Rack Support

38 Upper Impinger plate

39 Rack

40 Lower Impinger plate

41 Top Trim

42 Rear Panel

43 Side Panel LH

45 Door Skin

46 Door Handle

47 Door Inner

48 Door Choke

49 Door Seal (wide)

50 Bottom Trim

51 Side Panel RH

52 Door Assembly

53 MenuKey Dust Cover

54 Power switch (On/Off)

55 Membrane GM Version

Version 2.0


57 Display Assembly

& Header Version 2.0

58 MenuKey Socket

59 Sounder

60 Cool-down pan

DV0036

30Z1299

11K0005

SA257

32Z4028

30Z1178

30Z0231

SA339

SA340

DV0492

DV0114

SA211

DV0275

SA266

DV0187

SA329

DV0091

DV0501

32Z1066

SA331

DV0168

DV0305

DV0037

DV0092

SA111

DV0052

30Z1318

DV0055

Ref.

No.

Description

61 Oven tray

62 Handle Assembly

63 Griddle

64 Griddle carrier

65 Chicken Griddle

(SA350+DV0221+ DV0267)

66 GM Membrane Version 3.0


68 Display Assembly

Header Version 3.0

70 Diode Assembly

71 Solid State Relay

72 Fibre Optic Logic PCB

73 Magnetron Cooling Duct LH

74 Magnetron Cooling Duct RH

— Door seal sealant ( tube )

— Stirrer cover sealant ( tube )

— Grease Filter Cartridge

— Microswitch interlock Spring

Part No.

MC3175

SA267

DV0221

SA350

SA133

DV0254

DV0249

30Z1324

11M0364

30Z1632

11K0013

DV0039

DV0040

31Z0186

31Z0527

SA340

31Z1247


32Z3539 Issue 5

18

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

Before this test is carried out the oven PREHEAT temperature must be set to 0ºC as this enables the oven to be used in Microwave ONLY mode. On completing the test the Oven PREHEAT temperature should be restored to its previous setting.

EC402s Version 2.0

To set the PREHEAT temperature to 0ºC

1. Switch the oven on and immediately press the Edit Preheat function key, the ENTER

PREHEAT TEMP screen will display ( Note this screen is available for 5 seconds )

2. The oven display shows the current PREHEAT setting, make a note of this temperature

3. Enter 0,0,0 for 0ºC and press Save.

4. The display will now show the initial Edit Preheat/Profile screen for 10 seconds then the cold standby screen.

Press the PREHEAT pad, the oven will not preheat but the READY TO COOK screen will appear in the display.

EC402s Version 3.0

To set the PREHEAT temperature to 0ºC

1. Switch the oven on and immediately press the Edit Preheat Temp function key, the OVEN

TEMPERATURE screen will display ( Note this screen is available for 5 seconds )

2. The oven display shows the current PREHEAT setting, make a note of this temperature

3. Hold down the

<<

— for 0ºC and press Save.

4. The Categories screen will appear in the display.

Test procedure:

1. Fill one beaker ( glass or plastic ) with one litre ( 1.78 pints ) of tap water at about 20ºC( 68ºF ) and measure the water temperature.

( Use a thermometer with a

1

/

10

, 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

Version 3.0 Press the lower RH function pad below the display to enter

Manual Mode

Time to 1 minute 3 seconds, Power to 100% and Fan to 10%.

Press the Start pad and wait until the counter reaches zero.

4. Take the beaker out immediately stir the water with a plastic implement and measure the water temperature.

Calculate the temperature rise of water in the beaker.

The temperature rise of the water should be within the following range:

Temperature Rise

15ºC ( 27ºF ) Minimum

20ºC ( 36ºF ) Maximum

Manual Mode:

If this screen does not appear

MANUAL MODE is set to OFF and must be changed to ON in the oven

PROFILE.

Version 3.0

Switch Oven OFF then ON and immediately press the lower of the 4 pads on the RHS of the display. In

OVEN PROFILE change Manual

Mode to ON

Version 2.0

Switch Oven OFF then ON and immediately press the Profile pad. Press change to set OVEN

MODE to PROGRAM/MANUAL

Note:

Power Output is affected by the line voltage under load.

For correct Power Output measurement the line voltage under load must be correct.


32Z3539 Issue 5

19

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 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 3 )

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 Power Transformer.

4 Using a D.M.M., check the resistance of the windings. Results should be as follows: a Mains winding between tags

Approx. 1.1

Ω b High Voltage winding

Approx. 60

Ω c Filament winding between terminals

Less than 1

Ω

c b

5 Using a Megger, test the insulation resistance between:

Primary winding and chassis

Filament winding and chassis

Pass if over 10 M

Ω

Pass if over 10 M

Ω

One end of the High Voltage winding is connected to the chassis, so this is not tested.

a

2. High Voltage Capacitor Test

You will need:

A Digital Multi-meter (D.M.M.)





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 on next page.


32Z3539 Issue 5

20

PROCEDURES FOR PRINCIPAL COMPONENTS TEST (2)

( High Voltage Capacitor Test continued, ensure steps 1-4 on previous page have been completed)

Between Terminals

Between Terminals and Case

Pass if approximately 10 M

Ω

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 M

Ω

3. High Voltage Rectifier Test

You will need:







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

Conducts one way only

Short Circuit both ways

Conducts one way, leaks the other

FAIL

PASS

FAIL

FAIL

4. Magnetron Test

You will need:


A Magnetron can be tested for an open filament or a short circuit by carrying out a continuity check.






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.


32Z3539 Issue 5

21

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 signal to the Logic PCB. The switches operate as follows:

Door Interlock Arrangement: Switches shown in Door Closed position

RHS

LHS

L

1

Power In

Primary

switch

Monitor

switch

Secondary

switch

Power

Out

L

2

Logic

PCB

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

SW1

Primary

SW2

Left Side

Door closed

Logic PCB

SW4

Secondary

SW3


32Z3539 Issue 5

22


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.

The purpose of this procedure is to set the interlock so that when the door is opened more than 4mm the Oven microwave circuit is switched OFF.

The door closed position [Microwave circuit ON] is actually set with a 2mm opening to allow for heat expansion when the oven is operating at full temperature.

1

Release the 4 screws retaining each microswitch assembly

WARNING

DO NOT set the microswitch assembly at the bottom of the adjustment slots as this would result in the microwave circuit operating for a much larger door opening distance and cause potential microwave leakage from the oven.

2

Position the door open with a 4mm gap:

Place the two RED 4mm Spacers over the door seal at the top of the door on each side at the corner and carefully close the door ensuring the spacer is on the door seal.

RED Spacers

Smooth side of spacer to door seal

Door

Seal

Door

To set Microswitches SW3 & SW2 to OPEN

[OFF] at a door opening with a 4mm gap:

On the LHS of the oven, press down on the switch assembly to set SW3 to just click

CLOSED and then allow the assembly to move 1-2mm to just allow the switch to return to the OPEN position and tighten all 4 screws.

Repeat the procedure on the RHS of the


32Z3539 Issue 5

23

Spacer

Spacer

SW3

LHS

SW2

RHS

1-2mm

OPEN

CLOSED


3 Remove the 4mm 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 Fuse F4 and Tag 7 on the Relay

PCB Board.

Fuse 4

Tag 7

Replace the RED 4mm spacers on the door and over the corners of the seal as before.

RED Spacers

SW3 & SW2

Open Circuit

Door

Seal

Door

OPEN

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.

4

To confirm the oven operates at a 2mm door open position.

Replace the 4mm spacers with the two GREEN 2mm Spacers.

GREEN Spacers

SW3 & SW2

Door

Seal

Door

CLOSED

0.1

Check that microswitches SW2 and SW3 are in the CLOSED [ON] position and the Multimeter reads a minimal resistance.

If the meter reads Open Circuit, remove the 2mm spacers and repeat steps 1-4 moving the switch assemblies very slightly further down.

This procedure may need to be repeated several times to achieve a satisfactory arrangement.


32Z3539 Issue 5

24

PRINCIPAL COMPONENTS: Hot Air Motor & Controller 1

Convection and Fan Speed Control

The convection heat is provided by 5 elements located in the 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 inside the motor will operate and shut down the motor speed controller.

5

6

2

3

1

Step

4

Motor/ controller fault finding

Electrical supply into motor controller

Three phase connections to motor

Speed Controller connections to logic board

Motor thermal cut-out (short circuit)

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)

SA208 Hot Air Motor Assembly

8x 31Z4016

M5 Flange nut


32Z3539 Issue 5

25

PRINCIPAL COMPONENTS: Hot Air Motor & 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 to be adjusted from approximately 1500 rpm to 7000 rpm in steps of 5%.

Door Open = 1500 RPM

Door Closed (not cooking) = 3500 RPM

Door Closed (cooking) = as specified by program or setting

Motor Speed and Logic board voltage table

Fan speed %

Voltage dc

RPM Condition

Full

Speed

Door

Closed

Door

Open

Wire

27

Power Terminals

Wire 26

Motor Terminals

Blue Black Brown

Grey wire to Motor

Blue 0V

Yellow 0-10V

Red +10V

V

Displays and messages: LED status display

LED

LED Off

Meaning

Inverter Off / No supply

Long On & Off (1sec) Power On / Ready

LED On steadily Inverter Running

Long On (0.5 sec)/ short Off General Warning

Very Short On & Off (0.1sec) Fault Condition

Position

LED


32Z3539 Issue 5

26

4

5 5

ASE PH

TWIN


32Z3539 Issue 5

27

BLACK

BLUE

BROWN

GREY

GREY


32Z3539 Issue 5

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32Z3539 Issue 5

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32Z3539 Issue 5

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32Z3539 Issue 5

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32Z3539 Issue 5

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32Z3539 Issue 5

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32Z3539 Issue 5

34

Trouble-Shooting Guide

Is the problem Food Quality or Fundamental

Food Quality

Fundamental

Standard Food Quality Checks

• Check that the PREHEAT temperature is set correctly.

See User Manual.

• Check that the food being cooked has been stored at the correct temperature.

• Check that the correct program is being used.

Still Have a problem:

Select a Category.

• 2.0 Cold Food

• 2.0 Core Temperatures Low

Standard Electrical Checks

• Check that oven is connected to an

Electricl Power supply and that any trip that supplies the unit is not switched off.

• Check that the oven is switched on.

• Check the Electricl Power supply voltage at the input terminal block.

• Check that all fuses are intact.

• Check that the overheat stat has not tripped this can be checked by measuring the voltage across the Auxiliary transformer.

Still Have a problem:

Select a Category

.

• 1.0 No Display

• 3.0 Cavity Sensor Error

• 4.0 Magnetron / Over heat errors

Note : The following Diagnosis procedures may not expose all possible errors but have been included for general guidance.


32Z3539 Issue 5

35

OFF

OFF

1.0 No Display

Is Relay PCB

Active see D27

Is Logic PCB

Active ?

See D7 LED

ON

ON

Check cable from logic PCB to display is in place and no obvious wires are disconnected or shorted.

Still Have a problem?

Check 15 Way Ribbon

Cable between

Logic and Relay PCB.

Still Have a Problem?

Using spare display connect to Logic PCB

Still Dead

Spare Display

works

Replace

Display

Check Connection Output at Aux Transformer.

Check Power supply to Relay PCB

Check Fuse on Relay PCB

Still Have a Problem?

Replace Logic PCB


32Z3539 Issue 5

36

2.0 Cold Food

Check Convection

Temperature control

NO

Possible Temperature Sensor Fault.

Assuming sensor Ok then make sure door Light on logic PCB is on when door closed. If this is working then replace Logic PCB.

Also, check that convection motor is operational

OK

Check Current using clip on current meter through F7 and F8. When running Microwave only. You will need to reset the pre-heat temperature to 0 and enable manual control via the profile setting. Make

sure that there is a water load in the cavity.

Less than

5 Amps

More than

5 Amps

Check that the stirrer is rotating.

Yes

No

Carry out Microwave Output Test

LOW

OK

Replace stirrer motor and retest

Check Microwave Generating system

• Transformer

• Magnetron

• Capacitor

• Diode

Contact Merrychef Service

Department for Further assistance.


32Z3539 Issue 5

37

3.0 Cavity Sensor Error

Are there any Signs of

Cavity Fire

YES

Report to

Management and

Make Investigation

OK

Re-Start Oven

Activate Pre-heat

NO

Check Temperature

Sensor Resistance

NOT

OK

Replace Sensor

Retest

Is Led D19 on relay PCB ON

Yes LED is on.

N

Check door Switch

LED on logic PCB

LED is on

Check Heater

Elements

Replace if necessary

N

Check the Door Interlock

Switch.

Check The interconnecting lead to the logic PCB.

Is the temperature display saying too hot ?

Cavity Sensor error is caused by one of the following :-

1. The cavity did not heat by 100°C in the 10 Minutes

2. The cavity Exceed the set point when cooking by more than 40°C whilst cooking which indicates that the food load was on fire

Assume the Cavity is not too hot then:

Replace Sensor

Re-test and calibrate


32Z3539 Issue 5

38

4.0 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 I still have a problem.

Magnetron Error reported =

Magnetron or

Ambient

Ambient

Note :- Each Magnetron has a thermistor attached to it. The control unit will produce an error if the temperature exceeds

130°C.

Establish if the magnetron is actually getting hot.

Remember to take care given the High Voltage in the magnetron area.

Check sensor connections.

Replace Magnetron.

The Ambient Air Sensor is located on the

Relay PCB. Measure the temperature in the area with all the case work in place using a Thermocouple Meter

< 60°C

Check 15 ribbon Cable

-

Replace Relay PCB.


32Z3539 Issue 5

39

Temperature reading

> 60°C

Cooling Air Flow

Problem into control area.

Ambient Conditions too hot

APPENDIX 1:

TEMPERATURE SENSOR RESISTANCE DATA

Temperature Sensor Resistance

Temp °F

212

302

392

482

Temp °C

100

150

200

250

Min. Rate kΩ

11.490

2.803

0.950

0.3572

Standard

Rate kΩ

13.060

3.161

1.000

0.3865

Max. Rate kΩ

14.810

3.434

1.050

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.


32Z3539 Issue 5

40

APPENDIX 2:

MenuKey, changing oven menus

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:

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.g. 555

Do not remove the key during download sequence as this could corrupt the data on the key

The MenuKey CS

0A06

e.g.

MenuKey CS (checksum) confi rms the menus on this key are valid for the MenuKey Code.

MENUKEY2 DETECTED

MK CODE 555

MK CS 0A06

Download Upload

Download

4

Confi rm that the MenuKey Code and MenuKey CS are correct and press Download Function key to load the programs into the

Oven memory.

Note: Downloading from a

MenuKey will clear all the existing programs

Check that the key is correct then press the Continue function key to proceed with the

Download

Continue

MENUKEY2

DOWNLOADING

MENUKEY2

MENUKEY2 DETECTED

MK CODE 555

MK CS 0A06

Download Upload

WARNING

ALL OVEN PROGRAMS

WILL BE OVERWRITTEN

Exit Continue

MENUKEY2

VERYIFYING

On completion of the download press the Exit function key to return the oven to standby mode.

The display briefl y will show the following:

Oven Model No. Software

& MenuKey serial No.

The standby screen will then display

Remove the MenuKey and keep in a safe place.

Exit

.

Model No. 402S

Software

MK serial No.

1


32Z3539 Issue 5

41

MENUKEY2 DOWNLOAD

COMPLETE

CHECKSUM:0A06

Exit

OVEN COLD

PRESS PREHEAT

APPENDIX 2:

MenuKey, changing oven menus

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:

WARNING

Downloading from a MenuKey will clear all the existing programs

Do not remove the key during download sequence as this could corrupt the data on the key

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 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:

MenuKey Detected

Please Wait

Copying Programs from

MenuKey to Oven

Verifying Programs

Copied Correctly

MENUKEY2

MenuKey Copied

Successfully

The display briefl y will show the following : Oven Model No., Software & MenuKey serial No.

The Oven will then commence heating up to the PREHEAT temperature ready to cook.

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

CAT 002

CAT 003

CAT 004

CATEGORIES

CAT 005

CAT 006

CAT 007

CAT 008

EDIT

EDIT CATEGORY NAME EDIT A PROGRAM

CREATE MENUKEY

EDIT SCREEN

1

Enter a number for the MenuKey Code to identify the new MenuKey, use the +/- Function Pads.

For an explanation of the following features see

Setting the Oven Profi le Page 11

2

3

4

5

Set the Program Mode to ON or OFF,

Set Manual Mode to ON or OFF:

Enter the Lower Band temperature setting 15-75°C

Set the oven Temperature Scale °C

Insert a MenuKey and press START to copy the programs.

The display shows the following:

MENUKEY PROFILE

MenuKey Code: 000

Program Mode : ON

Temperature Scale : °C

Cooking Range: OFF

Cooking Range: OFF

START

WARNING

Any programs already

on the key will be deleted


Oven to MenuKey

Verifying Programs

Copied Correctly

MenuKey Copied

Successfully

The Display returns to the CATEGORIES screen and the Oven will heat up to the PREHEAT temperature ready to cook.

17


32Z3539 Issue 5

42

APPENDIX 3:

Cool Down Procedure

To cool down and clean a hot oven

Action

To commence Cool Down procedure Press

EC402s V2.0

Place Ice in cavity COOL DOWN MODE

PLACE ICE IN CAVITY

EC 402s V3.0

COOL DOWN MODE

PLACE LOAD IN CAVITYAND

PRESS START

Press

The oven cools down for approximately 30 minutes

Cycle ends

Continue

COOL DOWN MODE

OVEN HOT

PLEASE WAIT

( Also in Spanish)

COOL DOWN COMPLETE

READY FOR CLEANING

Start

COOL DOWN MODE

OVEN HOT

PLEASE WAIT

Turn oven off and ensure

Air Filters are clean

Switch oven off ready for cleaning


32Z3539 Issue 5

43

APPENDIX 3:

Cleaning procedure 1

• ALWAYS switch off at the electrical supply and allow oven to cool before cleaning

• 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 fi lters

& Oven Cavity

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 top impinger plate

Remove air fi lters both sides

Remove the rack and lift out bottom impinger plate

To remove grease fi lter push down and lift out

Undo fasteners

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 diffi cult areas leave to soak for 10 minutes.

Leave the oven door open during cleaning.

Use a non–abrasive nylon scrub pad/sponge to clean all internal surfaces and the inside of the door.

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.

4.

Replace clean oven parts

Grease Filter*

Top plate*

Bottom plate*

Air fi lters x2

DO NOT

USE TOOLS

DO NOT use the oven without clean

air fi lters and cavity grease fi lter in place

*When replacing impinger plates and the cavity grease fi lter use fi rm fi nger pressure to tighten fasteners

DO NOT USE TOOLS

20


32Z3539 Issue 5

44

APPENDIX 3:

Cleaning procedure 2

For the oven to operate at peak effi ciency, the cavity, door and air fi lters and grease fi lter 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 effi ciency 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

• ALWAYS switch off at the electrical supply before

cleaning

• Complete COOL DOWN procedure and allow the

oven and accessories to cool before commencing cleaning

• As required 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.

Hot surface

Hazard

Faults arising from neglect or misuse including use without clean fi lters in place are not covered by the guarantee. Service visits as a result of such faults will be chargeable.

DO NOT use the oven without clean air fi lters and cavity grease fi lter in place

START UP: OVEN COATING PROCEDURE ( clean, cold oven )

1.

With the oven clean and cold, spray Merrychef

Oven Protector onto the sponge

2.

Spread Oven Protector lightly onto all internal surfaces of the oven

3.

Spread Oven Protector lightly onto the internal surface of the oven door

4.

Switch the oven ON when the oven has reached operating temperature it will take

30 minutes to cure the

Oven Protector.

Note: oven protector turns light brown when cured

18


32Z3539 Issue 5

45

Part No.

DV0492

DV0606

DV0607

SA111

SA208

SA225

SA226

SA231

SA288

SA260

SA276

SA314

SA315

SA329

SA339

SA340

30Z1318

30Z1319

31Z0186

31Z0527

31Z1247

32Z4028

DV0037

SA273

DV0091

DV0092

DV0305

DV0203

SA274

DV0275

11H0364

11K0004

11M0117

11Z0298

30Z0217

30Z0231

30Z0957

30Z1340

30Z1155

30Z1349

30Z1177

30Z1178

30Z1230

30Z1233

30Z1331

30Z1242

30Z1251

30Z1294

30Z1295

30Z1298

30Z1299

SA234

30Z1315

APPENDIX 4:

Recommended spares lists

UK/EC

Description

HT DIODE PCB ASSY

RELAY PCB

DC VOLTAGE CONNECTOR 10 WAY

15 WAY 0.1 RIBBON CABLE ASSY

FUSE 1in 10A HRC

FUSE HOLDER 1IN (13A)

FUSE 1x1/4in 1A HBC (MAINS)

FILTER 16A (Threaded)

BLOCK TRANSFORMER B0012024

MAGNETRON Toshiba

20 AMP LITTELFUSE FLM020

30A FUSE HOLDER

60HZ TRANS MULTI 208 220 240

50HZ TRANS MULTI 208 220 240

1.0uF 2500V (50HZ Model)

1.1uF 2500V (50HZ Model)

0.88uF 2500V (60Hz Model)

MICROSWITCH WITH ROLLER

MAGNETRON COOLING FAN

CAPACITOR - MOTOR START - 2uF

DISPLAY ASSY + HEADER

THERMISTOR SENSOR ASSEMBLY

THERMISTOR 150MM + LEAD 900MM

2 POLE ROUND ROCKER SWITCH

MOTOR SPEED CONTROLLER

DOOR SEAL SEALANT - 1 TUBE

STIRRER COVER - SEALANT 1 TUBE

MICROSWITCH INTERLOCK SPRING

COOL DOWN TRAY

BOTTOM TRIM

CONTROL FASCIA ASSY V2.0/2.5

SIDE PANEL L/H

SIDE PANEL RH

DOOR SEAL (WIDE)

SEAL - CERAMIC COVER

CONTROL FASCIA ASSY V3.0

RACK V3.0

STIRRER COVER - CERAMIC

HEATER ELEMENT 220V

HEATER ELEMENT 240V

DOOR ASSEMBLY ( V2.0, V3.0 )

HOT AIR MOTOR ASSY

MAINS LEAD ASSY (EU) 4-CORE

MAINS LEAD ASSY (UK) 3-CORE

LOGIC BOARD MAIN ASSY V2.0/2.5

STIRRER MOTOR ASSY

LOGIC BOARD MAIN ASSY V3.0

AIR FILTER

CATALYST ASSY UPPER

CATALYST ASSY LOWER

REAR PANEL

GREASE FILTER HOUSING

GREASE FILTER CARTRIDGE

Qty Unit

1

1

1

2

1

1

1

1

1

1

1

1

2

5

5

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

2

4

1

1

2

1

1

2

4

4

2

2

1

1

2

1

1

1

5

3

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

TUBE

TUBE

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

EA

1-5

Ovens

1

1

1

2

1

1

1

1

1

1

1

1

2

5

5

1

2

1

1

1

1

1

2

1

2

1

1

1

2

2

1

2

1

2

2

1

1

2

2

2

2

4

4

2

2

1

1

2

1

1

1

5

3

Service

Kit

1

1

1

2

1

1

1

1

2

5

5

2

1

1

1

1

1

1

1

1

1

2

1

4

2

1

1

2

2

2

2

4

4

2

2

1

1

2

1

1

1

5

3

5-50

Ovens

3

3

3

6

1

1

1

1

2

3

2

2

6

15

15

1

6

3

3

3

1

1

6

3

6

1

3

3

6

6

3

6

3

6

6

3

3

6

6

6

6

12

12

6

6

3

3

6

3

3

3

15

9

First

Aid Kit

2

2

3

3

2

1

1

1

1

1

2

1

2

2

1

1

1

1

4

2

1

2

1

2

1

1

5

3

50-100

Ovens

6

6

6

12

1

1

2

2

3

6

4

4

12

30

30

2

6

2

2

12

12

6

6

6

6

12

12

6

12

2

12

12

6

6

6

12

6

12

24

24

12

12

12

12

12

6

6

6

30

18

6

12

6

Piece Qty for

600 Ovens

36

36

36

72

6

6

72

180

180

12

36

24

24

12

12

18

36

12

12

72

72

36

36

36

36

72

72

36

72

12

72

72

36

36

36

72

36

72

144

144

72

72

72

72

72

36

36

36

180

108

36

72

36


32Z3539 Issue 5

46

APPENDIX 5:

LOGIC PCB Connection Points and key features.

Spare input

(not used)

Temp Calibration

Display

Connecter

Relay PCB 15 way

Connecter

Door

Switch IP

Door switch

Indicator

ON when door closed

Remote data

point

MenuKey

Socket

Connector

Program memory storage.

Chip may be exchanged with New PCB if

PCB replaced.

Motor speed controller

Membrane panel connector

D7 Power LED

Indicates Logic PCB is powered

See Troubleshooting

Guide

Fibre Optic Magnetron

Detection

Solid State Relay

Heater regulation circuit

Fibre Optic

Detector 2 to RHS

Fibre Optic

Detector 1 to LHS

Magnetron 1

Magnetron 2


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Cavity

Temperature

Sensor

Input

Magentron

Overheat sensor

Inputs

Connector To

Logic PCB

U1 Ambient air temperature sensor

Display

Fuse

AC input from

Aux Transformer

Piezo sounder output

APPENDIX 5:

Relay PCB Connection Points and key features.

D15 Magnetron active

D16 Magnetron soft start

D19 Heater ON

D20 LED

ON

when power is on

OFF

when Microwave is operated.

Fuse

Not Used


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APPENDIX 6:

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. 31Z7066 3.0LD 402s Large Display UK/EU (FO / EMD)

Part No. 31Z7068 3.0LD 402s Large Display French (FO / EMD)

Part No. 31Z7071 4.3LD 402s Large Display UK/EU (FO / SSR / EMD)

Part No. 31Z7072 4.3LD 402s Large Display French (FO / SSR / EMD)

Part No. 31Z7073 4.4LD 402s Large Display US/EU

(FO / SSR / EMD / NSS / NPM / NEPT / NEP)

For QSR restaurants

Version 2.5

Part No. 31Z7067 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.

Convection Fan

Firmware:

This is where all of the oven operating instructions are stored. It can be changed by a CODEKEY

Fibre Optic Expansion

Menus:

This is where all of the

Information for menus is stored. It can be changed manually or by a MenuKey

LOGIC PCB

Door Sensor

Solid State Relay

Relay PCB:

Driven by the Logic PCB the Relay PCB controls all of the power around the oven.

Microswitches

Heater Elements

Magnetrons

Sensors


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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

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

Abbreviation

Code

Firmware Features

Supported

Firmware Version for 402s V3 ovens

2.8LD or lower

3.0LD 4.0LD 4.1LD 4.2LD 4.3LD

GM

4.4LD

QSR

NEPT Hidden Pre-Heat

NEP Hidden Profile

NPM Hidden Programs

SSR Solid State Relay

*

Note: this Table excludes KFC France ovens.

*Only when 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’

Subway and KFC

‘Quick Service Restaurants’ only including

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 & Table 2b)


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3.0 How to check your hardware fitted:

3.1 Remove the oven lid to reveal the Logic PCB. See Table 2a below

TABLE 2A

PCB Visual Check

Hardware fitted against PCB visual

SSR

Mag

Detect

Supports

Oven

Upgrade to V3

Allowable

Version /

Firmware

ONLY ON

V2 ovens

4.4SD

Device secured to plate

No pin strip

Device free standing

Pin strip fitted but no optics board

ON V2.5

ovens

4.4SD or higher

ON V3

Ovens

3.0LD or higher

TABLE 2B Hardware Upgrade

Hardware Upgrade

Technical Bulletin

Required

V2 oven

V2.5 oven

V3 oven

Adding Magnetron Detect

Adding Solid State Relay

TB114 TB114

TB122 TB122


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TABLE 2A

PCB Visual Check

Blue jumper fitted

Hardware fitted against PCB visual

SSR

Mag

Detect

Supports

Oven

Upgrade to V3

Allowable

Version /

Firmware

Optics board fitted

ON V2.5 ovens

4.4SD

ON V3 ovens

3.0LD or higher

SSR lead

SSR would be fitted if lead is present on PCB

ONLY ON

V3 ovens

3.0LD or higher

Fibre Optics Board + leads fitted

TABLE 2b: Hardware Upgrade

Hardware Upgrade

Technical Bulletin

Required

V2 oven

V2.5 oven

V3 oven

Adding Magnetron Detect

TB114 TB114

Adding Solid State Relay

TB122 TB122


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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.

Oven power switch

Lift cover to insert CodeKey into

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.

Switch the oven ON to activate the CodeKey, the screen will remain blank for approximately 1 minute before the startup screen displays.

After I minute the Oven will boot-up immediately press the

PAUSE pad to hold the oven information screen.







MenuKey Checksum F076 PAUSE>>

PAUSE pad


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4.3 To confirm a successful download check that the Software Version on the oven and the CODEKEY fob Label are the same.







MenuKey Checksum F076 EXIT>>

Software Version

CODEKEY

Fob

Label

Software: 4.3LD

Date: 00/00/07

CS: 0x9C71

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

Please Wait


MenuKey to Oven

Verifying Programs

Copied successfully

MenuKey Copied

Successfully

4. The display will show the start up sequence and the Oven will begin heating up.

5. Remove the MENUKEY


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APPENDIX 7: Electrical Installation Guide


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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 number on which error occurs (if applicable) -

Description of error

Suggestion for improvement to manual

Please return this form to:

Service Dept.

Merrychef Limited,

Station Road West,

Ash Vale, Aldershot

Hampshire GU12 5XA

United Kingdom

Tel: +44 (0)1252 371000 Fax: +44 (0)1252 371007

Internet address: http://www.merrychef.com

E-mail: [email protected]


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