402S Service Manual UK & EC Issue 5
Contents
1. m 5 ad N 1 J CET d M n 5 4 j B LE 3 A uu u WWE Xu TF E 4 T 1 4 DA d 1 fittest Las E 1 1 i a Heater Element 220V 650W Heater Element 240V 650W Magnetron Toshiba Magnetron Thermistor Assembly Convection Hot Air Motor Assembly Transformer 208 220 240V 50Hz Transformer 208 220 240V 60Hz HT Diode Assy PCB Fibre Optic HT Diode Assembly Non optic Magnetron Cooling Duct LH Magnetron Cooling Duct RH 402s Ovens Part N 32 3539 Issue 5 12 DV0606 DV0607 3021349 5 234 5 208 3021233 3021230 11H0364 11H0010 DV0039 DV0040 PRINCIPAL COMPONENTS Power Supply Electrical Supply Single Phase Electrical Supply Twin phase 2P N Earth 6990 1 L1 L2 Filter 16A 3021340 Fuse 10A HRC 3070217 3170500 3120499 Electrical Supply Lead Assembly Single Phase SA226 Electrical Supply Lead Assembly Twin Phase SA225 Terminal Block 3120447 Fuse 20A FLM 3021177 Fuse Holder 3041178 Fuse Holder 10 3070231 402s Ovens Part N 3273539 Issue 5 13 PRINCIPAL COMPONENTS Stirrer glass Shown removed Ne RN Stirrer behind stirrer glas2. F T i m _ ri Am nm 5 7 D 7 zh S NV i dE ee 1 li AE CEN E m rN N aM E 5 n gt a L t N Hardware fitted 2 against visual Oven Allowable Mag Upgrade Version Detect to V3 Firmware PCB Visual Check MME ON V3 ovens 3 0LD or higher v ONLY ON V3 v ovens SSR would be fitted if lead is 3 0LD or higher Fibre Optics Board leads fitted Technical Bulletin Required V2 V2 5 V3 oven oven TB114 TB114 TB122 TB122 402s Ovens Part N 3273539 Issue 5 52 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 the control panel e EE eee OO EE Lift cover to insert CodeKey into Oven power switch 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 minute the Oven will boot up immediately press the PAUSE pad to hold t
3. E N MOLOW N3MMNILS ED N aa SHY YOLOW 8333115 HOLOW NOLLO3ANOOD t 42018 WHI ac x SMOLOW ADET 350 SANVLIOA H3HIO N3AO 403 Nidai 2960 210N 63 o i 3215 200 S IOHINOO Ly 91551 IA VO VIG LINDYID 1N3W313 LLYM 059 SINS Mal H3NHOJSNY31 H3WNHOJSNYSI HAWHO4SNYHL LINDYID TOMLNOD S3201831NI S431V3H TANVd NOLLISOd 6012 0 MI NMOHS HOLMS Pe c MAWMO4SNYML SOVLIOA 1915 ALIAVO NOLLISOd 0350712 MOOC NI NMOS m SSHOLMS ALOM ons sin 91 Ops 9 1 5 Wo mon AM Ted 1 l X S DO TH31NI 4 Ses ay Pa EI LT ONIddVL 3LON SHI BSvHd 170 A11238802 4 S31VNIWITTI ALON SHY id Do 13 TE gt lt 31915 330 NAAOHS HOLPAS SNY Om gi Si wi EL ia ud 19 NOLMIS CY m i Sar YOLISNNOD HALNI noO101 f Bu HOLIMS SNIVW SH31V3H 831113 SNIVW LAW 11 enss LL
4. 100 1500watts Convection 3250watts External 595mm 23 0 inches Dimensions 585mm 23 0 inches 700mm 27 5 inches Weight 90kg 198lb s Construction Cavity 304 Stainless Steel Casework 402s Ovens Part N 3223539 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 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 minim
5. S IOHINOO 3SvHd JO LNO Q33IM IHY SUANMO4SNYML 3MNEN3 LL 1 00 418 ad ALOM SHI ONidd l A1ON SHY per m 25 Ui amp AIN 16 HU S 0 11 Fr 51 aa dak Sl 5L Fl EL CL 8 0 LT elke eta HALNI HOGA 04409 Alda PEIL 1621 E APA dil 1 SAA NaNO THOS ER T T dro T af JIN 441113 SNIVIN 31915 340 SNP di ZHOS 1 3 AVANOWOIN 431113 SNIVIN UT 01 07 d 100 or z E H2LIMS SNIVIN SAALYAH enss LLGEZCE ON SANA 3S Be MAAL OOM 40 18 383d0r3 11 0 4 Bis d 402s Ovens Part N 3273539 Issue 5 31 Sel NVAdSVId LIN2AID 1 _ N INSINS IS dad 9 55 SLM3IN313 dH31v3H LGEZTE ON
6. N aa daWAdDdEHridl Xv LM3WHOJSNVvHLI vol 84 EE 5 id LINDHID TOYLNOD 84 N SUIOTHSLNI 3SVHd 00 NSH 5 Oa SE SAONWSH SOLON IVIS HO NOILSNIJI3RHTSAT3SI NOLLSiSAMOO a 3AVAWOMOIN SM31V3H 7 1 55 TAN v d A T m EER m Ft GE a EN SHI ME el E Pod NI HALAS a ADHA e FL E df MEME ALTA j RE coo zz N RE NLama ES NY l mos EE i QMVOS 14 i ONHOOD Bneg Hi SHE E SMA TERI ELOUMLL j wood THIS 829 21607 i HE ANHA D oH Ha 99 p pe Ta oa MOM 2015397340313 SMOLOM
7. NO NOT OK Replace Sensor Check Temperature P Retest Sensor Resistance OK Re Start Oven Activate Pre heat Yes LED is on Is Led 019 on relay PCB ON Check Heater Elements Replace if necessary LED is on Check door Switch LED on logic PCB Is the temperature display saying too hot Check the Door Interlock Switch Check The interconnecting lead to the logic PCB Cavity Sensor error is caused by one of the Assume the Cavity is following not too hot then 1 The cavity did not heat by 100 C in the 10 Minutes Replace Sensor 2 The cavity Exceed the set point when cooking by Re test and calibrate more than 40 C whilst cooking which indicates that the food load was on fire 402s Ovens Part N 3223539 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 still have problem Magnetron Error reported Ambient Magnetron or Ambient Note Each Magne
8. g we A Mim pr Av P 2 i LI I d al RE a me gt L 1 PEL PY se 2 T LL La 4 r 1 7 e f ave em y 1 u a 4 E v E mv B 4 1 gt f ETT 024 di 5 js se T M Device AE 491 n ILILILILIEE secured to gt 2 z 7 z 4 j NC TET k i s M 8 qi 4 J E ae EL i l p 1 MEE T steel 04 T hz dIE KO PL d ng Bat 5 m Ed Ed ETE pec E a nos E LIES E 4 at few 5 gt i I 1 F E al E E 1 17 L 2 4 es d i 4t 5 I mm z T TE x ee B 2 4 r D 7 P 3 1 Remove the oven lid to reveal the Logic PCB See Table 2a below Hardware fitted TABLE 2A against PCB visual Mag PCB Visual C
9. Merrychef Version 3 0 Version 2 0 4025 SERVICE amp PARTS MANUAL This manual covers UK EC models manufactured from ISSUE 5 Version 2 0 Serial No 000745 001199 Version 3 0 Serial No 001200 onwards 23 09 2008 CAUTION MICROWAVE EMISSIONS DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE GENERATOR OR PARTS CONDUCTING MICROWAVE ENERGY TABLE OF CONTENTS ale iode EE IE N eee 3 Product specifications ssenari aaa 4 Installation instructions RR ER Ee Ee ee ee ee ee ee 5 EE Main features control panel Version 2 0 7 Main features control panel Version 3 0 8 Principal components 9 Principal components LHS 10 Principal components Control 11 Principal components Back View 12 Principal components Power Supply 13 Principal components Cavity Parts amp KFC Accessories 14 Principal components External panels amp Parts 15 Principal components Electronic control panel assembly 16 Pans Male ee ee ei sued 17 18 Procedure for Power output measurement 19 Proce
10. a t d TE 2 ET arcc AW1dSI0 JOMINOO YILT SNIVIN 804 ABOZ ALOM 64 i A 30 LNO SUANMO4SNVHL 8 M3IAMOJSNY3 L 39v KI rn ef 1916 ALIAVO g 11706 EIS rT 16 iro EN ZJN E EE 035072 na 4m 3AVANOMWOIN dii 13 SNIVA 7 csi 5 amp 3H2LM amp 1 ONIddVL ILON SHIT GN 55 ONIddVL SHY cd l L por PE T T T ud oo IE EST GU EF LI Lich SHH T zi EE EE EE L4 Wolds HLYON 5 98 1 M31V3H SNIV LAW walvaH 2 09 SMOOTMSLNI HOLIMS SNIVIN SH31V3H EN NE LEEN EO ENE EER iN et ET ESE ES DE N EE AE GE ONE SEE EE EEN EE N ERROR EEN ETE ONE ONE NE EE GEE ELE GE EG N GE EE ONE EE ON A EEN ENG ee 1 402s Ovens Part
11. amu 91907 _ ___ VONIOOO EX A SMAL jy EE arms t 4231 MARA E Wee 93 32018 1vHINH3L 77 49 052 on ARE SMOLOW En H T re a 0 fi Se 5 E TOMLNO2 HALTIA SNIVIA EAIN MO4ONIddwI SEN LON d EN d AT 1 alt tal EMEN 1225222 3 4 4 2 c 4 NI MAAOHS i 3 lc c ANIYA 40 LNO SMANMO4SNVUL IHNEN 3sv3ld gt 9 YINYOISNWHL JOVLION euge A 1918 ALIAWS 1 84 eo EE 098012 j JE H c lt SSL Td SMIVIN 23A MAAOHE L dir FAN 3 LON 4 1 A0 ILON SH 1 io 1 A0 ILON SHY cd _ 1 M fi 1 ike Fd d i 2 4 1 i L
12. 72 o o sc SE ZHOS 18 21 U Ly HA1VAH ZHO9 HOLIMS 3S VHd NIML Z 3eIM AAOWSAY NI SNIVIA Q THOM 30 1S38 3dOf13 NI SNIVIA VOIHANV H LHON NI SNIVIN 402s Ovens Part N 3273539 Issue 5 2f ob anssi AVAdOVId 1 1 fC I 7 AES Mad 11 099 OL enss Th mr 5 31 878 4SLVSH 0 P E SE 1 1 i NI HINHOSSNYHL HE de SHY HOLOIN H3HulL E ANOJEN E E P HEEL MW2O EN 3049 2006 LINDHO E HOLOW VIS OS ALIAVS 15415 ALIAWS MOLL2MNAd INVA 35113 TA 3AVAAOMSIN S31V3H 1 YILNI q3sc Er Glen dl La HALG UE Mona GE 05845 HOLOM da _ Ear 3
13. 2 EA 2 2 2 6 12 72 3021155 BLOCK TRANSFORMER B0012024 1 EA 1 1 6 3 3071349 MAGNETRON Toshiba 2 EA 1 2 2 6 2 72 302120 60HZ TRANS MULTI 208 220240 2 EA 1 2 2 6 2 72 N N 3021233 50HZ TRANS MULTI 208 220240 2 EA 1 2 2 6 12 7 3021331 10uF2500v 0 2 Model 11 EA 1 2 2 2 7 3021242 11uF2500v 60HZMode 1 EA 1 2 2 6 2 72 3071251 0 88uF 2500V 60Hz Model 2 EA 2 4 2 6 12 7z MICROSWITCH WITH ROLLER ha ek LOG 72 2 3021295 MAGNETRONCOOLING FAN 1 EA 1 1 6 3 CAPACITOR MOTOR START 2ur 1 EA 1 1 3 6 3 3071299 DISPLAY ASSY HEADER 1 EA 1 1 6 3 SA234 THERMISTOR SENSORASSEMBLY 2 EA 2 2 2 6 2 7 THERMISTOR 150MM LEAD 900MM 1 EA 1 1 1 36 3071318 2 POLE ROUND ROCKER SWITCH __ 1 EA 1 1 1 6 3 3071319 MOTOR SPEED CONTROLLER 1 EA 1 1 3 3120186 DOOR SEAL SEALANT 1 TUBE 1 1 1 2 6 2 7 3120527 STIRRER COVER SEALANT 1TUBE 1 1 1 2 6 2 7 312127 MICROSWITCH INTERLOCK SPRING 1 EA 1 1 1 3 6 3 L 3224028 COOLDOWNTRAY 11 56 2 12 7 DVvoo37 _ 1 EA 11111 2 2 SA273 CONTR
14. Cool down pan 3274028 57 58 59 402s Ovens Part N 3223539 Issue 5 18 PROCEDURE FOR POWER OUTPUT MEASUREMENT The power output specification 1500W this model is established under 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 0 C 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 0 C 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 0 C 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 0 C 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
15. N 3273539 Issue 5 32 N ua SH13010W MaMMILS SHY es N HOLON NOIL23ANOO ea Oma ana Gc X20718 TYNI wea SHOLOW SSN SAOWLION TY ASE 9NIdd 1 ABOT 36 1 SLON 64 gr ip c el som MANMO4SNVYML 39V11OA ONY 1916 ALIAVO NOLLISOd 09501 NI eed 350 S3HOLIMS JION BS sd LA d MOL INC E EL SMOOTYSLNI sy 91551 IA Ve VIG LIN2AID 1N3IN313 Mad LLYM 059 SLN3N313 831 3 H3WNOJSNYHIXOV vi 64 H3AHOJSNVHI VOL 84 u3WHOJSNVNI vol 4 LINDYID 1081NOO 93 S3201831N 32 5 200 LINDYID Su31v3H IVIS 2 S3lON NOLLISOd 035072 MOOO NI NMOHS H21IMS ALON LOOMLL ee 82d 21007 89 21607 god STOMINOO AO 31ON SH1 SNIddV 1 AO SHY s i T E 4 St im
16. use firm finger pressure to tighten fasteners DO NOT use the oven without clean DO NOT USE TOOLS When replacing impinger plates and the cavity grease filter air filters and cavity grease filter in place N 402s Ovens Part N 3223539 Issue 5 44 APPENDIX 3 Cleaning procedure 2 e ALWAYS switch off at the electrical supply and allow oven to cool before cleaning e 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 filters Wash all parts in warm soapy water Wash off using a clean cloth and plenty of amp Oven Cavity clean warm water Dry using a fresh clean cloth Remove air filters Remove the rack and lift Remove top impinger plate To remove grease filter both sides out bottom impinger plate push down and lift out Undo fasteners Undo fastener 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 2 3 4 Wear p
17. HANHOASNVAHL YAWYOASNVAL LINDYID TOH LNOO SUALVAH NOILONN A AM IVA ACLS 900 1915 HO ALIAVO SNIddV L ADE ASN SHOVL IOA HAHLO 11 A80Z ONIddVL A802 ASN ALON 64 ae Ea HANHOASNVHL AOVLIOA 1915 ALIAVO NOILISOd 5010 NI NMOHS HOLIMS Wooa 4ALON TANVd 3NVSSIN3IN 04 VL Elde OL Wi prar ayog 21901 HO1VOIONI SMS AV1dSIG nan 9 SL vl Lb OL GL er NOILISOd 35010 HOOG NI NMOHS SAHOLIMS 3 LON AMVONO9ZS AMVWIMd EMSSHT gj ZMS Sr 0 YOLINOW LMS SHY L SMOOTYALNI 1 TT tt 84 1 3 7110 9 09 ncr vAN ONIddV L ALON SH1 T id 1 sy 6 6 1 E uo 9 z9 s en nc GAIN ONIddVL ALON SHY AAVMOXOIN SUALVAH Ldf MOSNASSH19VW ear OES WOOT OL 3MIM SIL 318vO 9 3MIM ZHOS eas EE sd vdd 8 LL 94 LS lt 3115 440 NI NMOHS HOLIMS 44O NO SNIVW
18. 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 See Safety Code Page 3 1 Isolate the oven from the mains supply 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 amp compare results with table on next page 402s Ovens Part N 3223539 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 Pass if approximately 10 MQ 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 MQ 3 High Voltage Rectifier Test You will need Megger or similar resistance meter using 500V d c WARNING High voltages and large currents
19. 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 Primary SW 1 SW2 Left Side Door closed Secondary Logic PCB SW3 SW4 402s Ovens Part N 3223539 Issue 5 22 PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST 2 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 WARNING DO NOT set the microswitch The door closed position Microwave circuit ON is actually set with a 2mm assembly at the bottom of the opening to allow for heat expansion when the oven is operating at full adjustment slots as this would temperature result in the microwave circuit operating for much larger door 1 opening distance and cause Release the 4 screws retaining each microswitch assembly ME the oven 2 Position the door open with a 4mm Place the two RED 4mm Spacers over the door seal at the top of the door on each side at the corner and ca
20. Part N 32 3539 Issue 5 25 PRINCIPAL COMPONENTS Hot Air Motor amp 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 rom to 7000 rpm in steps of 5 ELEL RD 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 Voltage Condition dc 1999 100 10V 7000 Full Speed 9 ori Power Terminals Wire 26 20 2 1500 DE DEU 504826 Motor Terminals Blue Black Brown Em EE E E 8333333233 Blue Grey wire Yellow 0 10V to Motor Red 10V Displays and messages LED status display LED ________ Meaning 00000000 LED Off Inverter Off No supply Long amp 1sec Power On Ready LED On steadily Inverter Running Long On 0 5 sec short Off General Warning Very Short On amp 0 1sec Fault Condition 402s Ovens Part N 32 3539 Issue 5 26 KB W YOLOW H3HMILS nea SHY YOLOW 3HMHILS YOLOW NOLLO3ANOO SYOLOW 6 9155 NVASVIC 5 LN3IA3 T3 LLYM 099 S LN3IAN3 13 HALVAH H3INHOJSNVH LL XNV L
21. SAW 3SVHd LNO SYSWYOSSNVUYL 5 3 35931 rs i 1 EL Zi 90 50 3 AAYMOMOIW SY3LV3H BOSNES BOSNES 50 OW 13H 701 3H 37872 15 SHIM 14 NAAD 3 gt 94 EE 01 pn ovo 1 10 wy jedoun3 lt o _ __ can 48 SNIVW 3IA 31715 440 NI NAAOHS SNIN TE eos JajeaH 831113 SNIVMW 23 1 a YHON Zd 99 i 0 07 9 8 1 831112 5 LAW HOLIMS SNIVW SMALVAH S 9 55 LLGEZZE ON Hed 3STHA NIMU XOJE J3AOWSH _ Y 3SVHd lt i a ex Ms VOldAWY HLYON NI SNIVIW NIML 402s Ovens Part N 32 3539 Issue 5 33
22. 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 Open Circuit both ways FAIL discharged before commencing work 3 Remove all connections from the High Voltage Conducts one way only PASS Rectifier Short Circuit both ways FAIL 4 Using the Megger test for continuity in both Conducts one way leaks the other FAIL directions Compare results with the table 4 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 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
23. oven display shows the current PREHEAT setting make a note of this temperature 3 Hold down the lt lt for 0 C 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 20 C 68 F and measure the water temperature Use a thermometer with 1 1 0 1 degree gauge Manual Mode If this screen does not appear 2 Place the beaker in the centre of the cold cavity MANUAL MODE is set to OFF and must be changed to ON in the oven 3 Version 2 0 Press the Manual Function Pad to enter Manual Mode PROFILE Version 3 0 Press the lower RH function pad below the display to enter Manual Mode Set Time to 1 minute 3 seconds Power to 100 and Fan to 10 Press the Start pad and wait until the counter reaches zero Version 3 0 Switch Oven OFF then ON and im mediately press the lower of the 4 pads on the RHS of the display In OVEN PROFILE ch Manual 4 Take the beaker out immediately stir the water with a plastic implement Mode to ON Mic aa and measure the water temperature Version 2 0 Calculate the temperature rise of water the beaker Switch Oven OFF then ON and The temperature rise of the water should be within the following range immediately press the Profile pad Press change to set OVEN Temperature Rise MODE to PROGRAM MANUAL 15 C 27 F Minimum 20 C 36 F Maximum Note Power Ou
24. 059 SIN3W3 13 H31V3H J3NHOJSNVHL XII YHL 53 83 H3JINHOJSHY HL 13 Aid 93 A 3215 200 LINDY SUALYAH 5 p HOLISOd OOM MOOD NLINAAOHS HOLMS TANYd 000 ALON re lar star Bod i 508 01201 AW asia STOMLNOO 4240 0008 SL EL EL 10 80 50 ea L SH31V3H HOLOSNNO2 EI SHY TH MOGH ALEJ Av 134 i OL Jah TED 16 Se NIAD HOS i T gd 0 cas Dis e op 1700 T DE m pa e MN 1 35 gt d TOMINOO SNIVIN EAW 31915 340 NI N MOHS HOLS SHH 3SWHd JO LNO SU3WMOJSNYML 2 BEER i I 6 1 SN a aan 3 LE TER 2 a em 33 113 SNIYW 2 314 7 ONIddVL 310N SHT ONIddV L ILON SHY 1 1 zi ad 24 n f 07 0 1 So _ S 48 M31V3H Y31714 SNIVW LAWN 11 M3lIV3H 209 HOLIMS SNIVIN SH31V3H Z anss 1 5226 ON E
25. 4025 Ovens Part N 3223539 Issue 5 17 Part number identification chart 2 Ref Part No Ref Description Part No 32 Fuse Holder 30A 3071178 61 3175 34 Fuse Holder 10A 3020231 62 Handle Assembly 267 35 Grease Filter 2 parts SA339 63 Griddle DV0221 SA340 Stirrer Glass DV0492 64 Griddle carrier Rack Support DV0114 65 Chicken Griddle Upper Impinger plate SA211 SA350 DV0221 DVO267 Rack DV0275 GM Membrane Version 3 0 DV0254 Lower Impinger plate SA266 67 Front Panel Version 3 0 DVO249 Top Trim DV0187 Display Assembly 3021324 Rear Panel SA329 EF O O Header Version 3 0 Side Panel En SEU 70 Diode Assembly 11M0364 Door Skin DUO 71 Solid State Relay 3071632 Door Handle 2 72 Fibre Optic Logic 11 0013 73 Cooling Duct LH DVOO39 i DOO 115 74 Magnetron Cooling Duct RH DV0040 sak Poor Seal __________ Bottom Trim DV0037 Door seal sealant tube 3120186 Side Panel DVOO92 Door Assembly SAN Stirrer cover sealant tube 3120527 MenuKey Dust Cover DV0052 Grease Filter Cartridge SA340 Power switch On Off 3021318 Microswitch interlock Spring 3121247 TUS ____ Version 2 0 Front Panel Version 2 0 DV0036 NN EEN 36 37 38 39 40 41 42 43 45 46 AT 8 50 51 52 53 54 5 Display Assembly 3021299 amp Header Version 2 0 MenuKey Socket 11K0005
26. 49 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 Time 00000 Hours psy Door Operations 00049 E EE Software Version 4 1LD MenuKey Code 002 MenuKey Checksum 2076 PAUSE gt gt Firmware Version for 402s V3 ovens 2 8LD 3 0LD 4 0LD 4 110 4 2LD 4 3LD 4 410 or lower GM QSR Screensaver v NEN BMICCCCMAMENINESENENENEA MEEN e e weers x e Ei e e eene BEN MEd A ce 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 Quick Service Restaurants only including Subway and KFC 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 amp Table 2b 402s Ovens Part N 32 3539 Issue 5 50 3 0 How check your hardware fitted Z 7
27. 9379 39v110A i n e o3 1915 ALIAVO 84 MALVA 2926 100 21 ZL 2 2 m LEA _ tT 035079 317113 ZAN OO0 IN a vAN SSHOLAMS ILUN N AD ILON ETER SNIddv ILON SHY 24 3 7 a Fi a ioe ak tT 0 sso Gi z ti EE EE EN HIEON E 831114 SNIVN 2 SHO TH31NI 2509 H2LIMS SNIVIN SH31v3H NI SN 402s Ovens Part N 3273539 Issue 5 29 H3HHILLS SHY MOLOMN MH33MILS HOLON 418 _ 33dS HOLON cH TE c 48 j eem a 3n ec Ez MALI WHS p SYOLOW Sl AVEC SAAL TTY WIAD ABO Og b ALOM Te 15 ME 2 gb E oz em 3 0 0812 Cu em mc HAWMOASNYML MOTONY 1916 ALIAVO C3 HUUG HI BAAS i SAHAAWAS Manna LAAS T EM a E m Be 05 MOLINO 1 1 cV anssi NVAdOVId 1 1 914913 dad
28. EIER 3 y m 9E ate et SS 2 1 4 2 4 2 lt 1 E 4 LI 2 E 2 qi L3 E E3 s 5 m TAE dE YALWSH 331113 SNIVIN LAW a 3 EE SAOOTMALNI DES HOLIME SNIVW 5831 EE ENE EE 402s Ovens Part N 32 3539 Issue 5 28 L anssi IA VO VIG LINDAID AN3W3 14 Had LLVM 099 SH1 HOLOW 939915 SINK Hilvid ten 5 H TEE 1 n ON LIE PUSNYOISNVEL 56266 ON Hed 1 JE B ME E 57 SHY MOLOMN MaMHLLS URE UI uu utu Jii Liao TT in SOE SUNT 372082 IDEE enss NM MOS LE ZA ON 3H 3215 00 LINDHID SUALYAH 1915 HALNI D gt 5 ascn2 i HOL MS 3105 SNI1002 L wecae ADOT OL IM 31813 am 19 SYOLON E DML MET SSE LT mu ME 2 HALT SNIVN BEN 3104 84 FA STOHING SE a l 330 HELLS EL SHIA 40 LNO SUINHO4SNYUL 2UNEN3 3
29. Fibre Optic PCB Solid State Relay 402s Ovens Part N 3273539 Issue 5 9 3021024 3021298 3021340 SA276 SA288 3021294 5 202 3071295 3021242 3041251 3121261 11M0364 3021362 PRINCIPAL COMPONENTS Left Side Filter 16A Threaded Air filter Stirrer motor Assembly Microswitch SW3 Microswitch SW4 Door Hinge Assembly LH Motor Controller Thermistor Cavity HV Capacitor 2500V 1 0uF 50Hz models HV Capacitor 2500V 0 88 60Hz models HV clip Fibre Optic PCB 402s Ovens Part N 3273539 Issue 5 10 3021340 5 276 5 288 3021294 5 203 3021319 3071315 3021331 3021251 3121261 11 0364 PRINCIPAL COMPONENTS Control Box See Principal 5 POWER SUPPLY Description Fuse 10A 3020217 Gold resistor 220R 3070235 Relay Assembly 11K0004 Ribbon Cable 15way 1120298 Ribbon Cable 10way MenuKey 11M0117 Logic PCB Assembly Version 2 0 11K0002 Logic PCB Assembly Version 3 0 11K0012 Transformer LT Low voltage 3021155 Fuse 3020957 Sounder 257 Fibre Optic Logic 11K0013 402s Ovens Part N 32 3539 Issue 5 11 PRINCIPAL COMPONENTS Back view 7 mz sE N 1 n k 1 m 4 2 r ED 1 P 1 W 4 ia d E ES 4 T ce gt LE Ri
30. GEZZE ON Hed 5 NIMI 40418 NI SNIVW 402s Ovens Part N 3273539 Issue 5 34 Trouble Shooting Guide Is the problem Food Quality or Fundamental Operational Issue Food Quality Fundamental Standard Food Quality Checks Standard Electrical Checks Check that the PREHEAT temperature is e Check that oven is connected to an set correctly Electricl Power supply and that any trip See User Manual that supplies the unit is not switched off Check that the food being cooked has e Check that the oven is switched on been stored at the correct temperature e Check the Electricl Power supply voltage Check that the correct program is being at the input terminal block used e Check that all fuses are intact e Check that the overheat stat has not Still Have a problem tripped this can be checked by measuring Select a Category the voltage across the Auxiliary transformer 2 0 Cold Food Still Have a problem 2 0 Core Temperatures Low Select a Category e 1 0 No Display e 3 0 Cavity Sensor Error e 4 0 Magnetron Over heat errors Note The following Diagnosis procedures may not expose all possible errors but have been included for general guidance 402s Ovens Part N 3223539 Issue 5 35 1 0 Display Is Logic PCB Active See D7 LED OFF ON Check cable from logic PCB to display is in place and no obvious OFF ON wires are disconnected
31. Note In service operations when temperature setting during cook cycle PREHEAT is set to 0 C this message can appear when the oven is operated 402s Ovens Part N 3223539 Issue 5 FEATURES Electronic control panel Version 3 0 COOL DOWN 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 Display Panel error messages Error Message Magnetron 1 Overheat Ensure air filters are clean Allow oven to cool Magnetron 2 Overheat Ensure air filters are clean Allow oven to cool Magnetron 1 amp 2 Overheat Ensure air filters are clean Allow oven to cool Magnetron 1 Failure Magnetron 1 no microwave output Check power supply Magnetron failure FUNCTION PADS Magnetron 2 has overheated MAIN DISPLAY i2 MenuKey CANCEL PADS PAD FUNCTION 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 num
32. OL FASCIAASSYV2025 1 EA 1 1 6 3 DVoo91 SIDEPANELLIH 1 EA 1 1 2 aR 92 SIDEPANELRH 11564 1 1 2 2 DVO305 DOORSEAL WIDE 1 EA 1 1 2 2 7 DVO203 SEAL CERAMICCOVER 2 EA 2 2 2 6 2 72 SA274 CONTROLFASCIAASSYV3 0 1 EA 1 1 2 RACKVBO tT EA 1 6 3 DVO492 STIRRERCOVER CERAMIC 2 EA 2 2 2 6 2 7 15 SAT11 __ DOORASSEMBLY V20V30 __ 1 EA 1 1 2 2 SA208 HOTAIRMOTORASSY 1 EA 1 1 3 54225 MAINS LEAD ASSY EU 4CORE 1 EA 1 1 2 4 54226 MAINS LEAD ASSY UK 3CORE 1 EA 1 1 2 4 54231 LOGICBOARDMAINASSYV2025 1 EA 1 1 6 3 288 STIRRERMOTORASSY 1 EA 1 1 SA260 LOGICBOARDMANASSYV3O 1 EA 1 1 3 EA 2 2 2 6 12 7 SA314 CATALYSTASSYUPPER __ 1 1 1 1 SA315 CATALYSTASSVLOWER __ 1 EA 1 1 1 8 SA329 REARPANEL 1 EA 1 1 2 2 SA339 GREASEFILTERHOUSING 1 EA 1 1 2 2 SA340 GREASE FILTER CARTRIDGE 1 EA 1 1 2 8 402s Ovens Part N 3223539 Issue 5 46 APPENDIX 5 LOGIC PCB Connection Points key featu
33. Set the Program Mode to ON or OFF 3 Set Manual Mode to ON or OFF 4 Enter the Lower Band temperature setting 15 75 C 5 Set the oven Temperature Scale C WARNING Insert a MenuKey and press START to copy the programs d The display shows the following y Copying Programs from Verifying Programs Oven to MenuKey Copied Correctly 1111 TL The Display returns to the CATEGORIES screen the Oven will heat up to the PREHEAT temperature ready to cook MenuKey Copied Successfully temperature ready to cook 402s Ovens Part N 32 3539 Issue 5 42 APPENDIX 3 Cool Down Procedure To cool down and clean a hot oven 4025 V2 0 4025 V3 0 Cool Down procedure Press Place in cavity COOL DOWN MODE COOL DOWN MODE r PLACE ICE IN CAVITY PLACE LOAD IN CAVITYAND PRESS START Continue The oven cools down for COOL DOWN MODE COOL DOWN MODE approximately 30 minutes OVEN HOT OVEN HOT PLEASE WAIT PLEASE WAIT Also in Spanish Cycle ends COOL DOWN COMPLETE Turn oven off and ensure READY FOR CLEANING Air Filters are clean Switch oven off ready for cleaning 402s Ovens Part N 3223539 Issue 5 43 3 Cleaning procedure 1 For the to operate at peak efficiency the cavity door air filters grease filter must be kept clean A daily cleaning routine will ensure that you comply with the regu
34. ber 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 Magnetron 1 has overheated Blocked air filters Oven located near hot air source Oven being used empty Cooling fan failure Magnetron failure Magnetron 1 amp 2 have overheated Magnetron 2 Failure Magnetron 2 no microwave output Magnetron 1 amp 2 Failure Magnetron 1 amp 2 no microwave output Ambient Overheat Ensure air filters are clean Allow oven to cool exceeded limit Cavity Overheat Please contact service more than 295 C Temperature inside casing has Cavity temperature has exceeded 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 Heater Failure Cavity has not reached a One or more heater elements have failed temperature of 100 C 10 minutes and need to be replaced 402s Ovens Part N 3223539 Issue 5 PRINCIPAL COMPONENTS Right Side Cavity Overheat stat Motor Start Capacitor 2uF Blue Filter 16A Threaded Air filter Stirrer motor Assembly Microswitch SW 1 Microswitch SW2 Door Hinge Assembly RH Magnetron Cooling Fan HV Capacitor 2500V 1 1uF 50HZ models HV Capacitor 2500V 0 88yF 60HZ models HV Capacitor universal clip
35. d sequence by displaying the following The MenuKey Code e g 555 The CS e g 0A06 MenuKey CS checksum confirms the menus on this key are valid for the MenuKey Code Confirm 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 MenukKey will clear all the existing programs Check that the key is correct then press the Continue function key to proceed with the Download On completion of the download press the Exit function key to return the oven to standby mode The display briefly will show the following Oven Model No Software amp MenuKey serial No The standby screen will then display Remove the MenuKey and keep in a safe place as this could corrupt the data on the key Do not remove the key during download sequence 00000 C oj 2 68889 9 8 5 50 99 MENUKEY2 DETECTED MKCODE 555 MK CS 0 06 Download Upload Download 2 DETECTED ES MK CODE 555 MK CS 0A06 Download Upload WARNING ALL OVEN PROGRAMS WILL BE OVERWRITTEN Continue Exit Continue MENUKEY2 DOWNLOADING MENUKEY2 VERYIFYING MENUKEY2 DOWNLOAD Exit COMPLETE CHECKSUM 0A06 Exit Model No 4025 OVEN COLD Sofware PRESS PREHEAT MK serial No 402s Ovens Part N 32 3539 Issue 5 41 APPENDIX 2 MenuKey changing oven menus The Me
36. dures for Principal Component tests 20 21 Procedure for door interlock adjustment 22 24 Hot Air Motor and 25 26 reU gi Diagrami N 27 34 Troubleshooting Guide 35 39 Appendix 1 Temperature Sensor resistance data 40 Appendix 2 MenuKey download procedure V2 0 41 MenuKey download procedure 0 42 Appendix 3 Cool down amp Cleaning Procedure 43 45 Appendix 4 Recommended Spares List 46 Appendix 5 PCB connection Points 47 48 Appendix 6 Firmware revision 49 54 Appendix 7 Electrical Installation Guide 55 Merrychef Limited Station Road West Ash Vale Aldershot Hampshire GU12 SKA 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 402s Ovens Part N 3273539 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 It has been prepared to offer technical guidance for the 4025 range of Ovens Please remember that it is wiser not to attempt a service task if you are un
37. e SAI NALE MOS LE QTHOM 30 EENET SpE em LE HLYON NI SNIVIN 402s Ovens Part N 3273539 Issue 5 30 819115 gt DEE LZ SHY HOLOW dadAILS E N SOLOW M CH LO 1 co ca i 9 5 ce anna C 42008 L 1 ADE HAHID ABOE Hide SEN ALOM dAWNAOASMYd IHY MOLLESO ORENT ILON i BL THS SH 1 TE o 7 0 02 VYE El SMOOTS31NI 4 eb 9155 LINDYID l3 059 SLNSWS H31V3H 43 048 241 2 HAWAOHASMYHL A LINDY SUA1LYAH 53 Bd 13 93 3215 DOE 1915 ALIAVO SALON MOLLIS LAS cod WHS HAWE 1004 2D adi 7 Bod JeyBneg 21007 82d
38. e Model Serial Number Electrical Ratings and Manufacturers telephone number 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 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 ELECTRICAL SUPPLY CORD Electrical supply cord is situated on the rear of the oven AIR FILTERS Main intake for cooling air for internal components Must be clear of obstructions IMPINGER PLATES Upper amp Lower Direct the air in the cavity They must be cleaned on a regular basis and kept free of debris STEAM VENT PIPE Vents steam from the oven cavity 402s Ovens Part N 3273539 Issue 5 6 FEATURES Electronic control panel Version 2 0 PREHEAT COOL DOWN FAN SPEED PADS PANEL 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 D
39. ef products please contact the Service Department or your local Service Agent Tel 44 0 1252 378007 E mail technical support merrychef com 20Am 402s Ovens Part N 3273539 Issue 5 55 Single Phase loading L1 Brown 32 Amps viewed fram back of plug Plug Type single Phase 32 60309 EN60309 Li N E 40Amp 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 technical support merrychef com 402s Ovens Part N 3223539 Issue 5 56
40. gh limit Stat 3021024 2 Motor Start Capacitor 2uF Blue 3071298 3 Filter 16A 3021340 4 Air filter SA276 SA Stirrer inside cavity 213 6 Microswitch 1 SW2 SW3 SW4 3021294 7 Door Assembly 202 Door Assembly LH SA203 10 Motor Controller 3021319 11 Fuse 10 HRC 3020217 12 Gold resistor 220R 3020235 13 Relay Assembly 14 Ribbon Cable 15way 15 Ribbon Cable 10way MenuKey 11K0004 1120298 11 0117 16 Logic Version 2 0 2 5 11K0002 16 Logic PCB Assembly Version 3 0 11K0012 17 Transformer LT Low voltage 30 1155 18 Fuse 19 Gland Nut 20 Heater Element 220 650W Heater Element 240V 650W 3070957 3120500 31720499 DV0606 DV0607 21 Magnetron Toshiba 3071349 22 Magnetron Thermistor Assembly 23 Convection Hot Air Motor Assembly 24 Thermistor Cavity 25 HV Capacitor 2500V 1 0 50Hz Models 25 HV Capacitor 2500V 0 88uF 60Hz Models 25A HV Capacitor clip universal 26 HV Capacitor 2500V 1 1uF 50 2 Models 26A HV Capacitor clip universal SA234 SA208 3021315 3021331 3021251 3121261 3021242 3121261 27 Transformer 208 220 240V 50 2 3071233 27 Transformer 208 220 240 60 2 28 Diode Assy 29 Electrical Supply Lead Assembly 29A Electrical Supply Lead Assembly Twin Phase 30 Terminal Block 31 Fuse 20A FLM 3021230 11 0010 5 226 5 225 3120447 3021177
41. he oven information screen OVEN INFORMATION Oven On Time 00028 Hours Magnetron On Time 00000 Hours Door Operations 00049 Software Version 4 0LD MenuKey Code 002 MenuKey Checksum F076 PAUSE PAUSE pad 402s Ovens Part N 3223539 Issue 5 53 43 Toconfirm a successful download check that the Software Version on the oven and the CODEKEY fob Label are the same OVEN INFORMATION Oven On Time 00028 Hours Magnetron On Time 00000 Hours Door Operations 00049 Software Version 4 3LD MenuKey Code 002 MenuKey Checksum F076 EXIT gt gt Software Version Software 4 3LD CODEKEY pate 00 00 07 Fob cs 0x9C71 Label merrychef 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 Copying Programs from Verifying Programs MenuKey Copied Please Wait MenuKey to Oven Copied successfully Successfully BERE LL EIEN The display will show the start up seguence and the Oven will begin heating up Remove the MENUKEY ples 402s Ovens Part N 3273539 Issue 5 54 APPENDIX 7 Electrical Installation Guide WARNING EQUIPOTENTIAL This appliance must be eart
42. heck SSR Device free standing Supports Oven Upgrade Technical Bulletin Required V2 V2 5 oven oven Adding Magnetron Detect TB114 Adding Solid State Relay TB122 402s Ovens Part N 3273539 Issue 5 51 V3 oven TB114 TB122 Allowable Version Firmware ONLY ON V2 ovens 4 4SD ON V2 5 ovens 4 4SD or higher ON V3 Ovens 3 0LD or higher UOISIASU E o lt Blue jumper gt E 4 3 E 4 m E 7 vi TA REJ F f 1 gr NI LT im 1 MENT A qn mec 1 z aet 2 J Bib c 1 E me y 1 Ie poc b 7 L E i 3 1 We a ww F EF bi m P a 1 1 4 i r 44 1 GE a EE 1 5 1 al 5 i TM 7 z a i 1 Eur 4 i TT a de EE board fitted i Titte 200 HEFEFFEPEFRETSFFQTENE ES gt ji 4 j J nw i M 1 1 a pr 13 TEL Lai nd e m p 0 1 2 E ET a 5 NE s i 5 MAL n 1 44 gt 2 78 p J
43. hed Failure to do so An Equipotential Earth point is provided on the may result in electric shock and death rear panel of the oven for independent Earth GND connection The Oven must be connected to a separate electrical supply and installed by a qualified and approved electrician WARNING HIGH LEAKAGE CURRENT Earth suitably rated isolating switch with a 3mm contact gap on connection is essential all poles should be fitted for each oven installed Phase Loading Diagram Other Electrical Supply Twin Phase Equipment loading L1 L1 Brown 16 5 Blue 16 Amps Black Yellow Green Phase Loading Oven loading per phase is not equal therefore we recommend RED that other electrical equipment is connected to L3 Circuit Breakers OM TWIN PHASE en back or p Circuit Breakers should be rated at 204 per Phase eae 2 and be Time Delay Motor Start Type European Type C L3 Not used Plug Type SINGLE PHASE wn a Circuit Breakers should be rated at 40A per Phase 32Amp and be Time Delay Motor Start Type European Type C IEC 60309 EN60309 L1 L2 N E Earth Leakage Circuit L3 is not used If the oven is connected to an Earth Leakage Circuit Breaker device this should allow a minimum of 30 milliamps earth current without interupting the circuit If you are in any doubt about your electrical supply seek the advice of a qualified electrician For further information on Merrych
44. imeter 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 402s Ovens Part N 32 3539 Issue 5 24 PRINCIPAL COMPONENTS Hot Air Motor amp Controller 1 Convection and Fan Speed Control The convection heat is provided by 5 elements located 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 lt returns through the removable grease filter at the back of the cavity and into the fan Convection motor The convection motor Is 3 phase AC motor having a maximum speed of 7200 rom 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 1 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 Ohms 4 Ohms Black or Brown or Blue to Earth Open circuit SA208 Hot Air Motor Assembly 8x 3124016 M5 Flange nut 402s Ovens
45. ions 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 cm 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 402s Ovens Part N 3223539 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 4025 VVV F P C RTT ZZ Example 402S2205BK2GMEU Model No 4025 220V 50Hz L1 L2 N Earth supply MenuKey Revision 1 General Market EU Supply Control Country Voltage Region Voltage ac Phase Arrangement A General 208 208V L N E 30 Amp Electronic Market 220 220 230 240 230 240 L1 L2 N E US Kingdom C USA 2 P Gnd 20 Amps EU D 2 P Gnd 30 Amps Power See Rating Label Requirement Power Output
46. ired hygiene standards and will help to maintain and prolong the efficiency 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 e ALWAYS switch off at the electrical supply before cleaning e Complete COOL DOWN procedure and allow the and accessories to cool before commencing cleaning Hot surface As required wipe out spillages with disposable paper wipes Faults arising from neglect e NEVER use steel wool knives or harsh abrasives misuse use 2 clean on any part of the oven filters in place are not covered by the guarantee Service visits as a result of such faults will be As with all electrical appliances it is wise to have the chargeable electrical connections inspected periodically AN DO NOT use the oven without clean air filters and cavity grease filter in place START UP OVEN COATING PROCEDURE clean cold oven t 4 3 4 With the oven clean Spread Oven Protector Spread Oven Protector Switch the oven ON cold spray Merrychef lightly onto all internal lightly onto the internal when the oven has Oven Protector onto the surfaces of the oven surface of the oven door reached operating sponge temperature it will take 30 minutes to cure the Oven Protector Note oven protector turns light brown when cured
47. isplay 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 Display Panel error messages POWER PADS CANCEL PADS PAD FUNCTION 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 ERROR MAGNETRON 1 Magnetron 1 has overheated Blocked Air filter s Oven located near hot air sources Oven being used empty ERROR MAGNETRON 2 Magnetron 2 has overheated Cooling fan failure ERROR MAGNETRON 1 amp 2 Magnetron 1 and 2 have overheated CAVITY SENSOR ERROR Cavity temperature exceeds more than 50 C above PREHEAT Indicates combustion fire in oven cavity
48. nuKey System automatically changes all the cooking programs on the oven from a pre programmed electronic key To change the menus on the oven Do not remove the key WARNING during download sequence Downloading from will clear as this could corrupt all the existing programs 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 Copying Programs from Verifying Programs MenuKey Detected MenuKey to Oven Copied Correctly MenuKey Copied Please Wait Successfully I ULL The display briefly will show the following Oven Model No Software amp 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 EDIT CAT 601 CATEGORIES CAT 002 CAT 003 1 Enter a number for the MenuKey Code to identify the new Menukey use the Function Pads Ln MEE For an explanation of the following features see Setting the Oven Profile Page 11 2
49. o the 4025 Oven this Appendix has been produced stating the following 1 0 An overview of the control system for 4025 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 3127066 3 0LD 402s Large Display UK EU Part No 3127068 3 0LD 402s Large Display French Part 3127071 4 310 402s Large Display UK EU Part 3127072 4 310 402s Large Display French Part 3127073 4 4LD 402s Large Display US EU FO SSR NSS NEP For OSR restaurants FO FO 558 558 EN EN Version 2 5 Part No 3127067 4 ASD 4025 Small Display UK EU FO 1 0 The 4025 Control System The control system of the 402s is based upon the following fundamentals Logic Controls and monitors all aspects of the oven and stores all Firmware and Menu Data Fibre Optic Expansion Menus This is where all of the Information for menus is stored be changed Firmware This is where all of the oven operating instructions are stored It can be changed manually or by a MenuKey by a CODEKEY Solid State Relay ET Relay PCB Heater Elements Driven by the Logic PCB the Relay PCB controls all of the power around the oven 402s Ovens Part N 3273539 Issue 5
50. or shorted Is Relay PCB ACNE Still Have problem Check 15 Way Ribbon between Logic and Relay PCB Using spare display connect to Logic PCB Still Have a Problem Display Still Dead works Replace Check Connection Output Display at Aux Transformer Check Power supply to Relay PCB Check Fuse on Relay PCB Still Have a Problem Replace Logic PCB 402s Ovens Part N 3223539 Issue 5 36 2 0 Cold Food Check Convection Temperature control NO OK Possible Temperature Sensor Fault Check Current using clip on current Assuming sensor Ok then make sure meter through F7 and F8 When door Light on logic PCB is on when door closed If this is working then replace Logic PCB 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 Also check that convection motor is operational Less than More than 5 Amps o Amps Check that the stirrer is rotating Yes No Carry out Microwave Output Test Replace stirrer motor and retest LOW OK Check Microwave Generating system Contact Merrychef Service Department for Further Transformer assistance Magnetron Capacitor Diode 402s Ovens Part N 3273539 Issue 5 37 3 0 Cavity Sensor Error YES Report to Management and Make Investigation Are there any Signs of Cavity Fire
51. 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 402s Ovens Part N 3223539 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 Monitor switch RHS LHS _ i L1 ru Primary Secondary switch 2 switch Power Powerin Out 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
52. refully close the door ensuring the spacer is on the door seal Spacer RED Spacers Smooth side of i door seal Door Seal SW3 LHS SW2 RHS To set Microswitches SW3 amp SW2 to OPEN OFF at a door opening with a 4mm gap On the LHS of the oven press down on the 1 2mm 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 OPEN CLOSED Repeat the procedure on the RHS of the 402s Ovens Part N 32 3539 Issue 5 23 PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST 3 3 Remove the 4mm spacers and open and close the door 2 or 4 times to allow the parts to work together Set Multimeter Resistance and connect the meter to Fuse F4 and Tag 7 on the Relay PCB Board Replace the RED 4mm spacers on the door and over the corners of the seal as before RED Spacers SW3 amp SW2 Open Circuit Door Seal Door The meter should now read open circuit if not repeat steps 1 amp 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 amp SW2 Door Seal Door Check that microswitches SW2 and SW3 are in the CLOSED ON position and the Mult
53. res Spare input Relay PCB 15 way not used Temp Calibration Connecter Display Connecter Door Switch IP Door switch Indicator ON when door closed oO 5 Eo 5 Remote data point MenuKey Socket Connector Program Motor speed D7 Power LED memory storage controller Indicates Logic PCB Chip may be powered exchanged See Troubleshooting Membrane panel Guide Ee connector Fibre Optic Fibre Optic Fibre Optic Magnetron Detector 2 to RHS Detector 1 to LHS Detection Solid State Relay Heater regulation circuit Magnetron 1 rat ri 3 22 DEDE MEER WE rtp 1 Magnetron 2 ad E 402s Ovens Part N 3273539 Issue 5 47 APPENDIX 5 Relay PCB Connection Points and key features BTE Jd 015 Magnetron Temperature 2 D16 Magnetron Sensor ES soft start Input S5 Magentron D19 Heater ON Overheat sensor Inputs 020 LED E ON when power is T OFF Connector To Logic when Microwave is operated 01 Ambient air temperature sensor Display 8 TEE Fuse Fuse Sa Not Used input from Aux Transformer Piezo sounder output 402s Ovens Part N 3223539 Issue 5 48 APPENDIX 6 Firmware guide As result of on going changes upgrades t
54. rotective rubber For difficult areas leave Wash off using a clean Replace clean oven gloves and protective to soak for 10 minutes cloth and plenty of clean parts glasses carefully spray Leave the oven door warm water to rinse top Grease Filter Merrychef Oven Cleaner open during cleaning sides and back of oven Top plate onto the internal surfaces Use a non abrasive Dry using a fresh clean Bottom plate of the oven except door nylon scrub pad sponge cloth or paper towel Air filters x2 seals to clean all internal sur Wipe the outside of the DO NOT spray directly faces and the inside of oven with a damp cloth DO NOT into the fan opening at the door USE TOOLS the rear of the oven filter use firm finger pressure to tighten fasteners When replacing impinger plates and the grease N DO NOT USE TOOLS DO NOT use the without clean air filters and cavity grease filter in place 402s Ovens Part N 3223539 Issue 5 45 APPENDIX 4 Recommended spares lists UK EC First 1 5 5 50 50 100 Piece ty for 46 7 2 1100004 RELAYPCB 1 EA 1 1 3 EA 1 1 1 6 3 11202998 15WAYO 1RIBBONCABLEASSY 1 EA 1 1 1 6 3020231 FUSEHOLDERTIN T3A 3 EA 3 9 18 3020967 FUSE 1x1 4in HBC MAINS 1 EA 1 1 1 83 302130 FILTER 16A Threaded
55. s SA291 Grease Filter 2 parts SA340 SA339 Stirrer Glass DV0492 Rack Support Not shown DV0114 Upper Impinger plate SA211 Rack DV0275 Lower Impinger plate SA266 Parts 35 amp 37 Contact Service Department KFC Accessories 65 Chicken Griddle SA133 Cool down pan 3274028 Oven tray MC3175 Handle Assembly SA267 Griddle DV0221 Griddle carrier SA350 Chicken Griddle SA350 DV0221 DV0267 SA133 402s Ovens Part N 32 3539 Issue 5 14 PRINCIPAL COMPONENTS External Parts Control Panel See page 16 8 Door Assembly D Air Filter SA276 Top Panel DV0187 Rear Panel 29 0091 Door Skin DV0501 Door Handle 3221066 Door SA331 Door Choke DV0168 Door Seal wide DVO305 Door seal sealant tube 3120186 Bottom Trim DV0037 Side Panel RH DV0092 Door Assembly SA111 402s Ovens Part N 3273539 Issue 5 15 PRINCIPAL COMPONENTS Electronic Control Panel Assembly Version 2 0 Version 3 0 MenuKey Dust Cover DV0052 Power switch On Off 30 1318 Membrane Version 2 0 DV0055 Front Panel Version 2 0 DV0036 Display Assembly amp Header Version 2 0 3071299 MenuKey Socket 11K0005 GM Membrane Version 3 0 DV0254 Front Panel Version 3 0 DV0249 Display Assembly amp Header Version 3 0 3071324 402s Ovens Part N 3273539 Issue 5 16 Part number identification chart 1 Ref No Description Part No 1 Cavity Hi
56. sure 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 MQ 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 e lf 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 connect
57. tput is affected by the line voltage under load For correct Power Output measurement the line voltage under load must be correct 402s Ovens Part N 3273539 Issue 5 19 PROCEDURES FOR PRINCIPAL COMPONENTS TEST 1 1 Power Transformer Test You will need A Digital Multi meter D M M 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 Isolate the oven from the mains supply 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 resistance of the windings Results should be as follows Mains winding between tags Approx 1 1 Q be High Voltage winding Approx 60 BONA C Filament winding Less than 1 Q between terminals o Using Megger test the insulation resistance between Primary winding and chassis Pass if over 10 MO Filament winding and chassis Pass if over 10 MO One end of the High Voltage winding is connected to the chassis so this is not tested 2
58. tron has a thermistor attached to it The control unit will produce an error if the temperature exceeds 130 C 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 Establish if the magnetron is actually getting hot Remember to take care given the High Voltage in the magnetron area lt 60 C Temperature reading Check sensor connections Replace Magnetron Check 15 ribbon Cable Cooling Air Flow Problem into control Replace Relay PCB Ambient Conditions too hot 402s Ovens Part N 3223539 Issue 5 39 APPENDIX 1 TEMPERATURE SENSOR RESISTANCE DATA Temperature Sensor Resistance Temp F Temp C Standard Max Rate Rate 00 302 2 803 3 161 3 434 R 200 C 1 5 Note These resistances will only be in stable temperature as the sensor has a slow response time 402s Ovens Part N 3223539 Issue 5 40 APPENDIX 2 MenuKey changing oven menus The MenuKey System automatically changes all the cooking programs the oven from a pre programmed electronic key To change the menus on the oven 1 Ensure the power switch is OFF 2 Liftthe 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 downloa
59. um 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 Note NEVER Install an oven above fryers The ELS grills griddles or any other recommended clearance major heat source required for air flow 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 402s Ovens Part N 3223539 Issue 5 5 FEATURES On Off SWITCH This is used to turn the oven On or Off IT DOES NOT ISOLATE INTERNAL WIRING FROM THE MAINS SUPPLY MenuKey The MenuKey System automatically changes all the cooking programs with an electronic key and allows program names to be identified OVEN CAVITY The oven cavity is mainly constructed from stainless steel panels It must be kept clean GREASE FILTER The grease filter must be cleaned on a regular basis and kept free of debris RACK The cooking rack should be removed daily and cleaned HOT AIR FAN Situated behind the grease filter and circulates the hot air through the cavity RATING PLATE The rating plate is situated on the rear of the oven and states th
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