Mealstream 500 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 C Example CTM524505MK Mealstream EC501, High speed fan 230-240V, 50Hz, Series 5 electronic controls & MenuKey CTMx Fan Speed v Voltage f c Frequency Control Type p Phase MK MenuKey C Catalytic Converter CTM3 = Low speed CTM5 = High speed 22 = 220-230V EU 24 = 230-240V UK 50 = 50 Hz 60 = 60 Hz 2 = 2 phase MK = MenuKey fitted C= EC503 Catalytic Converter 5 = Electronic CD2 = Rotary Dial Controls 1 = 1 phase Omitted Power Requirements Refer
Installation instructions: Installation Instructions for Mealstream 500 series Combination Ovens Power Supply Requirements The Mealstream 500 series 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 Models with electronic controls 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.
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 3 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 3 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 For Tim Hortons see APPENDIX 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 14 13 12 6 11 7 10 8 9 No Description EC 501/2/3 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 B 4 Fuse holder 30amp ( FLM Series ) 30Z1178 30Z1178 4A Fuse 20 amp Littlefuse FLM020B 30Z1177 30Z1177 6 Mains terminal block 31Z0149 31Z0149 7 Filter ( Heater circuit
Principle components: Right side 22 21 13 20 16 No 17 10 9 Description EC 501/2/3 RD 501 520000 520000 Door spring long 40C1141 40C1141 10 Door arm stop assembly 11C0279 11C0279 13 Door arm assembly 11C0300 11C0300 9 Door spring short 9 A 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 sensorC 50E123 50E123 Note A: see page 17 for parts Note
Principle components: Top view 60 61 23 23 24 24 25 25 26 26 27 27 28 No Description EC 501/2/3 62 RD 501 23 Magnetron 30Z0264 30Z0264 24 Resistor Gold 470 R 30Z0283 30Z0283 25 HT diode 11C0266 11C0266 26 Capacitor 1.
Principle components: Door & cavity roof 67 67a 72 71 Note: for Tim Hortons see Appendix 8 No 67 67a Description EC 501/2/3 Stirrer glass & long seals Stirrer glass short side seal 71 Door seal kit 72 Door choke RD 501 40C0954 40C0954 790052 790052 11C0292 11C0292 790007 790007 Air Filters 81 81 No 81 Description Air filter panel (removable) Mealstream Ovens 32Z3387 Issue 3 EC 501/2/3 40C0868 RD 501 40C0868 Page 16
Principle components: Heater Element, Catalytic Converter & Cavity parts: CTM5_, [EC501] 78 69 76 74 77 68a CTM5_, [EC502] 70 78 79 77 74 68a 77 76 CTM5_, [EC503] 77 78 80 76 74 77 68a CTM3_ [EC501, RD501] 68 69 74 77 No Description Part No. 68 Heater element (2.5kW) 40C0954 68a Heater element (3.
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 47 Description Part No.
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 17 Primary switch 11 Power Out Power In Monitor switch 14 N 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: EC501, EC502 & EC503 34 29 33 32 31 73 30 No Description Part No.
Manual control panel assembly: RD501 38 39 40 40 35 29 38 44 34 41 33 29 38 44 45 41 38 No Description Part No.
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 EC501/2/3 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 30amp ( FLM Series ) B B 30Z1178 30Z1178 30Z1177 30Z1177 4A Fuse 20 amp Littlefuse FLM020 6 Mains terminal block 31Z0149 31Z0149 7 Filter ( Microwave circuit ) 30Z0997 30Z0997 8 Filter ( Heater circuit )
Part number identification chart: No Description EC501/2/3 RD501 35 PCB Assembly ——— 38 Red Neon ——— 316030 39 Timer ——— 30Z0991 40 Potentiometer 5k ——— 40C0892 41 Amber Neon ——— 316031 43 Panel assembly ——— 11C0307 44 Pushbutton ——— 31Z0349 45 Control knob Red/Grey ——— 11C0173 45 Control knob Blue ——— 11C0406 46 Cable Gland 31Z1070 31Z1070 47 Gland Nut 31Z1082 31Z1082 48 Mains Cable 3 Core 31Z0148 31Z0148 49 Motor shaft screen 40C1005 40C1005 50 Hot a
Circuit diagram: EC501, EC502, EC503 Mealstream Ovens 32Z3387 Issue 3 Page 26
Circuit diagram: RD501, CTM3__CD2 Mealstream Ovens 32Z3387 Issue 3 Page 27
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 Mealstream 501 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.
APPENDIX 2: Cleaning procedure Mealstream 502, Mealstream 503 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.
APPENDIX 3: PCB Connection Points and key features, EC501, EC502 & EC503 11C0291 Issue 5 Cavity sensor 50E123 Relay PCB Relay PCB °C Link Mealstream Ovens 32Z3387 Issue 3 Page 31
APPENDIX 3: PCB Connection Points and key features EC501, EC502 & EC503 11C0377 Issue 2 Menukey Temperature Calibration Relay PCB Relay PCB °C Link Mealstream Ovens 32Z3387 Issue 3 Page 32
APPENDIX 3: PCB Connection Points and key features EC501, EC502 & EC503 11C0212 Issue 11 Relay PCB Logic PCB Transformer 1 (LHS) Transformer 2 (RHS) Soft start common relay Heater switch Return from door switch & 0H Mag stats Logic PCB Neutral Live Earth Mealstream Ovens 32Z3387 Issue 3 Page 33
APPENDIX 4: Transformer Upgrade In partnership with our supplier Tabuchi, we have developed a multi-tap transformer that will output 208V, 220V & 240V. There are 2 models for 50Hz and 60Hz power supply. Should you need to change a transformer to any Mealstream 501 product, you should use the new 30Z1233 ( 50Hz power supply ) or 30Z1230 ( 60Hz power supply) multi-tap transformer, see matrix below.
APPENDIX 5: Hot air motor replacement procedure 1 we have improved the hot air motor assembly by enhancing the wave trap and balancing the impeller which is now fitted by a grub screw to a flat on the shaft. The tolerances to manufacture the motor shaft have also been tightened to improve the fit of the balanced impeller. Parts required: 10C0192 service kit (consists of the following parts): Part No.
APPENDIX 5: Hot air motor replacement procedure 2 Step 9 Fit new wave trap Pt. No. 40C1201 to cavity. See figures 1(a) & 1(b) (Making sure it is centred in the hole) Ensure wave trap is fitted correctly and not caught around the edge of the hole. See figure 2 Figure 1(a) Pt. No. 40C1201 Figure 2 Rear of cavity Note: Ensure wave trap is fitted correctly and not caught around the edge of the hole. Pt. No. 101520 Figure 1(b) Pt. No.
APPENDIX 5: Hot air motor replacement procedure 3 Step 10 Fit new hot air motor assembly Pt. No. 11C0472 (see diagrams below) Make sure the motor shaft is centred in the hole A) Fit motor assembly Pt. No. 11C0472 and secure finger tight with flange nuts & washers. B) Push the alignment tool (40C1211) onto the motor shaft and ensure initial step of the tool locates into the wave trap.
APPENDIX 5: Hot air motor replacement procedure 4 Adjusting alignment procedure To ensure correct alignment of the assembly there are 2 procedures that may be required: Procedure 1 The 4 bolts holding the wave trap to the cavity need to be loosened off sufficiently to allow movement of the wave trap. See figure 6 (see Alignment tool figure 8) You must then slide the alignment tool onto the motor shaft, keeping pressure on the rear of the tool only and not applying any sideways pressure.
APPENDIX 5: Hot air motor replacement procedure 5 Step 11 With the alignment correct Reconnect motor wires at terminal block. See figure 9a & 9b Step 12 Fit new impeller to motor shaft. See figure 10a & 10b (ensure grub screw lines up with the flat on the shaft) Fit the screw to the impeller and wind down until you feel it touch the motor shaft. Then gently push and pull the impeller back and forth to verify that the screw has located in the slot.
APPENDIX 6: Temperature Sensor replacement Mealstream ovens manufactured before March 2004 If you are required to fit a new temperature sensor to a Mealstream 501 oven on a service call, you need to follow the procedure below to verify that the sensor is holding firm in the pocket. The diagram below shows the area of the thermistor causing the problem.
APPENDIX 7: Fuse change (FLM20) 1 Mealstream ovens manufactured before March 2004 Brief description: 13A anti-surge fuses Pt. No. 30Z0168 are no longer manufactured these are now replaced with FLM020 fuses Pt. No. 30Z1177 for the Microwave circuit on all Mealstream 501 ovens. To replace a fuse on an oven manufactured before March 2004 and fitted with this fuse type it is necessary to replace the fuses and fuse holders with FLM 020 type. Part No.
APPENDIX 7: Fuse change (FLM20) 2 6. Push fit the new fuses Pt. No. 30Z1177 into the fuse holders. 7. Fit new label Pt. No. 31Z2092 over the existing label leaving the F5 and F1 still showing (C) 8. Power up the oven and check machine functions correctly. (Care should be taken when powering up ovens with covers removed). If fuse still blows, check microswitch setup is correct and replace if necessary. 9. Turn off the power and isolate the oven from the mains power supply. 10. Replace covers.
APPENDIX 8: Tim Hortons Ovens 1 This appendix list the parts and procedures for Tim Hortons Mealstream 501 models which are a vend type oven pre-programmed from a MenuKey. In order to carry out the Power Test on Tim Hortons variant Ovens, the Icon Pad programs on the control panel need to be switched to Engineering Program Mode.
APPENDIX 8: Tim Hortons Ovens 2 PROCEDURE FOR POWER OUTPUT MEASUREMENT The power output specification, 1425W on this model is established under IEC 705 standard method. This method is only workable in Laboratory controlled conditions. An approximate method is as follows: To carry out this test the Icon Pads need to be switched to ENGINEERING MODE PROGRAMS See previous page 1 Fill one beaker ( glass or plastic ) with one litre ( 1.
APPENDIX 8: Tim Hortons Ovens 3 2 Door and cavity roof: 1 2 8 4 6 7 5 3 No Description Part No. 1 Stirrer glass assy. ( inc.
APPENDIX 8: Tim Hortons Ovens 4 Tim Horton special parts: 12 16 13 15 14 No Description Tim Hortons Part No.
APPENDIX 8: Tim Hortons Ovens 5 Tim Hortons control panel N M MENU KEY K K Preheat L M L Cancel O M Icon Cook Pads N MenuKey™ O Quarter, Half & Full Batch Load For 240V model No Description Part No.
APPENDIX 9: PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST (1) The door on the Mealstream oven is monitored by three microswitches. These are used in the conventional “Primary, Secondary and Monitor” switch arrangement shown below. The switches operate as follows: Door Interlock Arrangement L1 Primary switch Switches shown in Door Closed position 11 Secondary switch Power Out Power In L2 17 Monitor switch 14 1. Monitor switch ( 14 ,Top left-hand Side ).
PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST (2) Please Note DO NOT attempt to carry out the following procedure unless you have the following tools and parts. Continuity Meter Spacer Door Spacer Kit Part No. 10C0171 No. required Part No.
PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST (3) Step 2: Insert S10 10mm spacer into door. (See figure 1 below for inserting spacer correctly). Interlock Step 3: Remove S10 10mm spacer and insert S1 1mm spacer into the door and close the door. Step 4: Remove S1 1mm spacer and insert S5 5mm spacer into the door and close the door.
PROCEDURE FOR MICROWAVE EMISSIONS TEST (1) Warning Check for radiation leakage after servicing. Should the leakage be more than 4mW/cm² Inform Merrychef service centre immediately. After repairing or replacing any radiation safety device, keep a written record for future reference this requirement must be strictly observed. In addition, the leakage reading must be recorded on the service repair documentation while in the customer’s premises.
PROCEDURE FOR MICROWAVE EMISSIONS TEST (2) • Readings must be below 4mW/cm². If a level greater that 4mW/cm² is observed, this should be reported to Merrychef Service Department immediately. • In any case, notes should be kept of the leakage that is observed. In terms of level and position on the oven. This should be kept with the service documentation. Control Panel Door Perimeter Rear and Side Covers Left & right Side Air Filters.
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.
