S E R V I C E M A N U A L Part No. 32Z3387 Issue No.
Table of Contents Safety Code ...........................................................................3 Product Specifications ...........................................................4 Installation Instructions ..........................................................5 Error Codes and Diagnostics.................................................6 Main Features........................................................................7 Electronic Controls ..................................................
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 501 range of Combination Microwave Ovens. Please remember that it is wiser not to attempt a service task if you are unsure of being able to complete it competently, quickly, and above all safely.
Product specifications: Model Number: CTMx v f c p MK Example CTM524505MK Mealstream 501, High speed fan 230-240V, 50Hz, Series 5 electronic controls & MenuKey prefix x Fan Speed v Voltage f c Frequency Control Type CTM 3 = Low speed 5 = High speed 22 = 220-230V EU 24 = 230-240V UK 50 = 50 Hz 60 = 60 Hz p Phase 5 = Electronic 2 = 2 phase CD2 = Rotary Dial Controls 1 = 1 phase Omitted MK MenuKey MK = MenuKey fitted Power Requirements Refer to rating Plate Power Output: CTM3 Microwave 100% Con
Installation instructions: Installation Instructions for Mealstream 501 Combination Ovens Power Supply Requirements The Mealstream 501 oven should be connected to a suitable electricity supply, which can cope with the switching-on surge that occurs with certain types of catering equipment, such as microwaves. Because of this requirement, we strongly recommend that a separate, suitably rated supply is installed for the oven.
Error codes and diagnostics The Mealstream EC501 will identify some of the most common problems by flashing an error message code in the time display window.
Main features: l a g b b c f m d j back panel e k k i h 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 HOT AIR VENTS Allows steam and excess pressure to escape from the oven cavity. It must be kept clear. c OVEN CAVITY The oven cavity is mainly constructed from stainless steel panels. It must be kept clean. d BAFFLE PLATE Forms the inside rear of the oven and covers the hot air circulation fan.
Electronic controls: j i b a g h a Stage LED's b Program & Time Display c Service Indicator d Air Filter Block Indicator e Convection Pad f Power Pads g Time / Program Number Pads h Temperature Set Pads i Cancel / Callback Pad j Program Pad k MenuKey socket Mealstream Ovens 32Z3387 Issue 2 f c e d k Page 8
Manual controls: a b c TEMP °C POWER % d TIME merrychef e f START Mealstream CD 2 g a Power Neon ( Amber ) b Temperature Control c Power Control d Timer e Start Push button f Cook cycle Neon ( Red ) g Heater Neon ( Amber ) Mealstream Ovens 32Z3387 Issue 2 Page 9
Procedure A - Power Output Test in accordance with BS EN 60335-2-90 Annex AA 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.
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 in the oven and close the door. Turn the oven on. Set the timer to 1:02.
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 .
Principle components: Left side 1 1A 2 2A 3 3A 4 4A 13 5 5A 12 14 6 11 7 10 8 9 No Description EC 501 RD 501 1 Fuse holder 30Z0231 30Z0231 1A Fuse 10 amp 30Z0217 30Z0217 2 Fuse holder 30Z0231 30Z0231 2A Fuse 10 amp 30Z0217 30Z0217 3 Fuse holder 30Z0231 30Z0231 3A Fuse 1 amp 30Z0957 30Z0957 4 Fuse holder 30Z0231 30Z0231 4A Fuse 13 amp 30Z0168 30Z0168 5 Fuse holder 30Z0231 30Z0231 5A Fuse 13 amp 30Z0168 30Z0168 6 Mains terminal block 31Z0149 31Z01
Principle components: Right side 22 21 13 20 16 No 17 10 Description 9 EC 501 RD 501 9 Door spring short 520000 520000 9 Door spring long 40C1141 40C1141 10 Door arm stop assembly 11C0279 11C0279 13 Door arm assembly 11C0300 11C0300 16 Door hinge assembly ( RH )* 11C0166 11C0166 17 Microswitch ( Secondary ) 30Z0240 30Z0240 20 Steam pipe 790046 790046 21 Steam vent guard 790061 790061 22 Temperature sensor 50E123 50E123 *See page 17 for parts Mealstream Ovens 3
Principle components: Top view 60 61 23 23 24 24 25 25 26 26 27 27 28 No Description 62 EC 501 RD 501 23 Magnetron 30Z0264 30Z0264 24 Resistor Gold 470 R 30Z0283 30Z0283 25 HT diode 11C0266 11C0266 26 Capacitor 1.
Principle components: Door, roof & heater element CTM3 67 69 68 67a 74 69 68a 74 70 No 67 Description Stirrer glass & long seals EC 501 RD 501 40C0954 40C0954 790052 790052 67a Stirrer glass short side seal 68 Heater element 2.5kW —— 790063 68a Heater element 3.0kW 40C0948 —— 69 Baffle 790047 790047 70 Baffle Side ( 2 No.
Principle components: ( not shown in main views ) 12 Left Hand Door Hinge Assembly 16 Right Hand Door Hinge Assembly (Includes all parts shown) (Includes all parts shown) 52 52 51 54 51 55 53 55 54 53 58 57 57 Hot air motor: Low Speed Stirrer motor assembly Hot air motor: High Speed 50 Motor shaft screen and seal assembly 49 No.
Input wiring details Green/Yellow 6 Blue Brown 48 46 No 47 Description EC 501 RD 501 6 Mains Terminal Block 31Z0149 31Z0149 46 Cable Gland 31Z1070 31Z1070 47 Gland Nut 31Z1082 31Z1082 48 Mains Cable 3 Core 31Z0148 31Z0148 Hot Air Motor connections and Wiring Mealstream Ovens 32Z3387 Issue 2 Page 18
Door interlock operation The door on the oven is monitored by three microswitches. These are used in the conventional “Primary, Secondary and Monitor” switch arrangement shown below. The switches operate as follows: Door Interlock Arrangement Secondary switch L Primary switch 17 11 Power Out Power In N Monitor switch 14 The diagram shows the microswitches in door closed position 1. Primary Interlock [ 11 , Bottom left-hand ] and Secondary Interlock [ 17 , Bottom right-hand ] Switches.
Electronic control panel assembly: Mealstream EC501 29 34 33 32 31 73 No 30 Description EC 501 29 On/Off Switch 30Z0503 30 Control Panel Assembly (without MenuKey) 11C0294 30 Control Panel Assy with MenuKey 11C0438 30 Locare Control Panel Assy with MenuKey 11C0458 31 Logic Board (without MenuKey) 11C0291 31 Logic Board with MenuKey 11C0377 32 Relay Board 11C0212 33 AC Ribbon connector 11M0116 34 DC Ribbon connector 11M0117 73 MenuKey Assembly 10C0148 Mealstream Ovens
Manual control panel assembly: Mealstream RD501 38 39 35 40 40 29 38 44 34 41 33 29 38 45 41 38 No Description RD 501 29 On /off switch 30Z0503 33 ac voltage connector 6 way 11M0116 34 dc voltage connector 10 way 11M0117 35 PCB Assembly 11C0295 38 Red Neon 39 Timer 30Z0991 40 Potentiometer 5k 40C0892 41 Amber Neon 43 Panel assembly 11C0307 44 Pushbutton 31Z0349 45 Control knob Red/Grey 11C0173 45 Control knob Blue 11C0406 Mealstream Ovens 32Z3387 Issue 2 44
Membrane panel circuit You will need: A Digital Multi-meter (D.M.M.) 1. 2. 3. 4. Isolate the oven from the mains supply. Remove the Logic Assembly from the Control Panel Housing. Unplug the membrane “tail” from the Logic PCB Assy. 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.
Part number identification chart: No Description EC501 RD501 1 Fuse holder 30Z0231 30Z0231 1a Fuse 10 amp 30Z0217 30Z0217 2 Fuse holder 30Z0231 30Z0231 2a Fuse 10 amp 30Z0217 30Z0217 3 Fuse holder 30Z0231 30Z0231 3a Fuse 1 amp 30Z0957 30Z0957 4 Fuse holder 30Z0231 30Z0231 4a Fuse 13 amp 30Z0168 30Z0168 5 Fuse holder 30Z0231 30Z0231 5a Fuse 13 amp 30Z0168 30Z0168 6 Mains terminal block 31Z0149 31Z0149 7 Filter ( Microwave circuit ) 30Z0997 30Z0997 8 Filter
Part number identification chart: No Description EC501 RD501 31 Logic Board (without Menukey) 11C0291 ——— 31 Logic Board with Menukey 11C0377 ——— 32 Relay Board 11C0212 ——— 33 AC Ribbon connector 6 way 11M0116 11M0116 34 DC Ribbon connector 10 way 11M0117 11M0117 35 PCB Assembly ——— 11C0295 38 Red Neon ——— 316030 39 Timer ——— 30Z0991 40 Potentiometer 5k ——— 40C0892 41 Amber Neon ——— 316031 43 Panel assembly ——— 11C0307 44 Pushbutton ——— 31Z0349 45 Control
Circuit diagram: EC501 Mealstream Ovens 32Z3387 Issue 2 Page 25
Circuit diagram: RD501, CTM3__CD2 Mealstream Ovens 32Z3387 Issue 2 Page 26
APPENDIX 1: MenuKey Download Procedure The MenuKey™ System automatically changes all the cooking programs on the numbered icon pads with the turn of a key. To change the menus on the oven: 1 Ensure the power switch is off. 2 Lift the MenuKey cover in the front panel of the oven and put the key in the keyhole Turn the key clockwise to the stop ( ¼ turn ). Do not remove the key at this stage. 3 Switch the power switch on.
APPENDIX 2: Cleaning procedure For the oven to operate at peak efficiency, the cavity, door and the 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.
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.
