Garland Mealstream CTM3, Service Manual

Page 1: ... 84 FGE84 I8AF G B 3 FFH8 4 8 0 84 FGE84 2 ...

Page 2: ...dure for Power output measurement 24 Procedures for Principal Component tests 25 26 Procedure for Door interlock adjustment and test 27 29 Procedure for building and fitting the door 30 34 Procedure for replacing door seal assembly 35 36 Procedure for removing shelf runners element cover 37 Procedure for replacing Heater Element 38 Procedure for replacing Hot air Motor assembly 39 Procedure for re...

Page 3: ...owave power for any service test or inspection within the microwave generating compartments check the magnetron wave guide or transmission line and cavity for proper alignment integrity and connections d Any defective or misadjusted components in the interlock monitor door seal and microwave generation and transmission systems shall be repaired replaced or adjusted by procedures described in this ...

Page 4: ...wired ensure that the power is turned off at the isolator switch Note The On Off switch on the oven is not adequate protection against electric shock as it does not isolate all of the internal wiring from the mains Upon completion of a service on a Mealstream oven or before reconnecting the appliance to the electrical supply for testing check all of the following points All internal electrical con...

Page 5: ...ty 10 2 inches 260mm 19 3 inches 490mm 14 2 inches 360mm 1 62 ft 45 86 litres Weight Nett Gross packed 198 lb s 90 kg 227 lbs 103 kg Construction Cavity Casework 304 Stainless Steel Settings Microwave Temperature Timer Programs 100 75 50 25 Convection only Off 300 F 350 F 400 F 440 F 480 F Up to 30 minutes per stage Cook Programs can have 3 cooking stages of up to 30 minutes for each stage Model N...

Page 6: ...dequate ventilation for air intake and exhaust and to allow access for cleaning filters you must allow a minimum of 2 inches 50 mm clearance at the sides and rear of the oven and at least 2 inches 50 mm above Air intake temperature should not exceed 110 F 45 C excessive temperature will lead to reduced operating duty cycle or premature ageing of internal components Failure to comply with these con...

Page 7: ...ngular racks or oven trays HOT AIR FAN Situated behind the baffle plate and circulates the hot air through the baffle plate over the heating element and around the edge of the baffle plate back into the cavity RATING PLATE The rating plate is situated on the rear of the oven and states the Model Serial Number Electrical Ratings and Manufacturers telephone number DOOR The door consists of a thermal...

Page 8: ...tion Pad f Power Pads g Time Preset Pads h Temperature Set Pads i Cancel Callback Pad j Program Pad N Menukey a b f g i j Electronic control panel h e MAIN FEATURES a b M M L K N O K Preheat L Cancel M Icon Cook Pads N MenuKey O Quarter Half Full Batch Load Tim Hortons control panel N MENU KEY ...

Page 9: ...al supply terminal block 31Z0149 31Z0149 7 Filter Heater circuit 30Z0997 30Z0997 8 Filter Microwave circuit 30Z0997 30Z0997 9 Door spring 40C1141 40C1141 9 Door springA Modification Kit 10C0177 10C0177 10 Door arm stop assemblyC 11C0279 11C0279 11 Microswitch Primary 30Z0240 30Z0240 12 Door hinge assembly LH B 11C0167 11C0167 13 Door arm assembly 11C0300 11C0300 14 Microswitch Monitor 30Z0240 30Z0...

Page 10: ...11C0166 17 Micro switch Secondary 30Z0240 30Z0240 21 Steam vent guard 790061 790061 22 Temperature sensor 50E123 50E123 59 Rubber stop 31Z1150 31Z1150 90 Cavity Vent Pipe 40C1013 40C1013 95 Diode Board assy with leads 11M0417 11M0417 113 Internal Filter RHS 40C1080 40C1080 118 Microswitch support bracketC 40C0851 40C0851 20 Steam pipe 790046 790046 59 PRINCIPAL COMPONENTS 90 95 Note B See page 17 ...

Page 11: ...eplaced by the Multi tap type Part No 30Z1230 No Description 208V 240V 23 Magnetron Panasonic 30Z1171 30Z1171 24 Resistor 470 R 30Z0283 30Z0283 26 Capacitor 0 88μf 2300V D 30Z0861 30Z0861 26 Capacitor 0 88μf 2500V Kit 10C0172 10C0172 27 Transformer E 30Z1230 30Z1230 28 Twin blower motor 30Z1145 30Z1145 60 25mm OD Flexible conduit 314402 314402 61 20mm OD Flexible conduit 314401 314401 62 Capacitor...

Page 12: ...240V 64 Hot air motor assembly 10C0192 10C0192 65 Capacitor motor start 6μF 30Z1148 30Z1148 88 Overheat Safety Thermostat 30Z1024 30Z1024 94 Hot Air motor Resistor Assy N A 11C0341 104 Twin Blower Resistor Assy N A 11C0477 Back view 64 65 88 94 104 PRINCIPAL COMPONENTS ...

Page 13: ... 3 4 Hex 109050 109050 86 Cavity roof seal short 790052 790052 89 Door Handle 40C1020 40C1020 Door Assembly Garland 11C0336 11C0336 Door Assembly Tim Hortons 11C0380 11C0380 Door Assembly Unbranded 11C0418 11C0418 106 Flat Washer S S M5 x 20 104036 104036 107 Nylon Washer 104250 104250 108 Spring Washer 31Z5005 31Z5005 109 Flat Washer S S M6 x 20 104054 104054 117 Nut M4 S S 31Z4015 31Z4015 93 67 ...

Page 14: ...Top Panel 790005 40C1181 99 Foot 32Z1052 32Z1052 100 Wire Rack 40C1011 40C1011 101 Crumb Tray RBR290X02 RBR290X02 111 Rear Outer Panel 40C0951 40C1180 114 Side bumper RMC6104 RMC6104 116 Air filter panel removable 40C0868 40C0868 119 Push fit bumper Rear Panel 31Z1187 31Z1187 121 Roof Corner cap n a 40C1113 122 Front pillar LH n a 40C1184 123 Front pillar RH n a 40C1185 119 101 96 99 98 97 111 PRI...

Page 15: ... before February 2004 Control panels now supplied are for the new style casework and not compatible with older models When replacing the control panel assembly remove the top trim On Off switch metal panel from the existing control panel and substitute this for the top trim on the replacement unit 32 31 33 34 29 30 73 No Description 208V 240V 57 Mesh washer 31Z5044 31Z5044 68 Heater element 40C094...

Page 16: ...d 11C0402 11C0403 No Description 208V 240V 30 Control Panel Assy with Menukey 11C0413 11C0413 31 Logic Board 11C0411 11C0411 32 Relay Board 11C0402 11C0403 No Description 208V 240V 30 Control Panel Assy with Menukey 11C0414 11C0414 31 Logic Board 11C0411 11C0411 32 Relay Board 11C0402 11C0403 US English No Description 208V 240V 30 Control Panel Assy with Menukey 11C0332 11C0332 31 Logic Board 11C0...

Page 17: ...1 Pin 790027 52 Roller 40C0752 53 M5 Hex hd s s Screw 101825 54 M5 stainless steel Nut 80X7003 55 LH Hinge bracket 790024 56 RH Hinge bracket 790025 58 Stirrer motor assembly 11C0324 not shown in main views 54 53 53 54 Right Hand Door Hinge Assembly Left Hand Door Hinge Assembly 55 Stirrer motor assembly 58 52 51 16 51 56 52 PRINCIPAL COMPONENTS ...

Page 18: ... L1 L2 Green Hot Air Motor connections and Wiring 208V 60 Hz L2 L1 240V 60 Hz L2 L1 PRINCIPAL COMPONENTS No Description All models 6 Electrical Supply Terminal Block 31Z0149 46 Cable Gland 31Z0500 47 Gland Nut 31Z0499 48 Electrical Supply Cord 3 Core 30Z1162 91 Electrical Supply Plug 50Amp Canada 31Z0298 ...

Page 19: ...mbly RH 11C0166 11C0166 10 17 17 Microswitch Secondary 30Z0240 30Z0240 10 20 Steam pipe S S 790046 790046 10 21 Steam vent guard 790061 790061 10 22 Temperature sensor 50E123 50E123 10 23 Magnetron 30Z1171 30Z1171 11 24 Resistor 470 R 30Z0283 30Z0283 11 25 HT diode 11C0266 11C0266 11 26 Capacitor 0 88μf 2300V D 30Z0861 30Z0861 11 Capacitor 0 88μf 2500V Kit 10C0172 10C0172 11 27 Transformer Multi t...

Page 20: ...clip 88mm 31Z0521 31Z0521 11 63 Filter 30Z0997 N A 11 64 Hot air motor assembly Kit 10C0192 10C0192 12 65 Capacitor Motor starter 30Z1148 30Z1148 12 67 Stirrer glass Assy Inc long seals 11C0319 11C0319 13 68 Heater element 40C0949 40C0948 14 69 Element cover plate 790047 790047 14 70 Baffle 11C0311 11C0311 14 71 Door seal kit 11C0292 11C0292 13 72 Door choke 790007 790007 13 73 MenuKey Assembly 10...

Page 21: ... 104036 104036 13 107 Nylon Washer 104250 104250 13 108 Spring Washer 31Z5005 31Z5005 13 109 Flat Washer S S M6 x 20 104054 104054 13 110 Door Spacer Kit 10C0171 10C0171 28 111 Rear Outer Panel 40C0951 40C0951 14 112 Internal Filter LHS 40C0962 40C0962 9 113 Internal Filter RHS 40C1080 40C1080 10 114 Side Bumper RMC6104 RMC6104 14 115 Shelf Support Tim Hortons 10C0174 10C0174 14 116 Air Filter Pan...

Page 22: ...ary to ensure that low readings are measured on the most sensitive range To prevent false readings hold the probe on the grip provided and move along the areas indicated on the following page The probe should be moved at 1 inch second 2 5cm With any casework removed the leakage should not exceed 4mW cm When measuring the leakage always hold the probe at 2 50mm from the test area using the probe su...

Page 23: ... reported to Garland Service Division 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 Figure 2 Door Perimeter Figure 2 Rear and Side Covers Figure 1 3 4 Left right Side Air Filters Figure 3 4 Fig 1 Fig 3 Fig 4 Fig 2 PROCEDURE FOR MICROWAVE LEAKAGE TEST 2 ...

Page 24: ...1 10 0 1 degree gauge 2 Place the beaker in the centre of the cavity 3 General Market Models Set Time to 1 minute 3 seconds and Power to 100 Wait until the counter reaches zero Tim Hortons Ovens With the oven in ENGINEERING MODE see Appendix 1 Press Pad 01 Cake and any Load Pad Quarter Half Full Wait until the counter reaches zero 4 Take the beaker out immediately stir the water with a plastic imp...

Page 25: ...sing 500V d c 1 Isolate the oven from the mains supply 2 Ensure that the High Voltage Capacitor is discharged before commencing work 3 Remove all connections from the High Voltage Capacitor 4 Using a D M M check for continuity between the terminals compare results with table on next page WARNING High voltages and large currents are present at the High Voltage Capacitor It is very dangerous to work...

Page 26: ...ure 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 WARNING High voltages and large currents are present at the High Voltage Capacitor It is very dangerous to work near thi...

Page 27: ...pply circuit to the transformers The Secondary interlock switch will cut off the microwave emission if the Primary switch have failed Note If operation of the Monitor switch has caused the Microwave Fuse to blow the Primary and Monitor microswitches must be changed as they may have been damaged by the high short circuit currents involved The door on the Mealstream oven is monitored by three micros...

Page 28: ...ogether Interlock Order SW1 Monitor 3rd SW2 Primary 1st Note both SW2 and SW3 activate together SW3 Secondary 1st Note both SW2 and SW3 activate together Step 1 Set the interlock so that they activate in the following order When closing the door When opening the door Continuity Meter Spacer No required Part No S5 Door Spacer 5mm 2 40C1118 S1 Door Spacer 1mm 2 40C1114 Door Spacer Kit Part No 10C017...

Page 29: ...seals meet Figure 1 Door top seal Door side seal Door spacer Interlock Order SW1 Monitor OPEN SW2 Primary OPEN SW3 Secondary OPEN Step 4 Remove S1 1mm spacer and insert S5 5mm spacer into the door and close the door If an oven fails this sequence then check the microswitches are functioning correctly and repeat steps 1 to 4 PROCEDURE FOR DOOR INTERLOCK ADJUSTMENT AND TEST 3 Please note It is very ...

Page 30: ...p 31Z5047 2 14 M5 stainless steel full nut 80X07003 23 15 Door seal set of 4 11C0292 1 16 CAF 30 Adhesive 31Z0186 As required 17 Door insulation set 40C0942 1 18 Outer Door Skin Check Oven Model 1 19 M3 counter sunk screw 31Z3094 7 20 Choke Plate 790007 1 21 SPACER KIT 10C0171 1 Tools required for door fitting M5 Nut runner Door Spacers S325 3 off S215 Flat head screw driver Long nose pliers 5mm o...

Page 31: ...oor frame into RHS Hinge assy Place door frame against cavity face and slide on LHS Hinge assy to the LHS Pivot pin of door frame 4 Fit Left hand side LHS Hinge assy to base assy loosely fit in place with bottom bolts 2 off M5 x 10mm 2 off M5 flat washer 2 off M5 shockproof washer Fit spacer to fill gap between Hinge assy and Inner side panel loosely fit spacer in place with 1 off M5 bolt x 16mm 1...

Page 32: ... two measurements together and divide by 2 Adjust hinge adjustment bolt so that the door is the distance calculated from the side of the door to the edge of the pin location hole and lock in position with lock nut Door hinge adjustment Edge of pin location hole Door 9 Fit door springs to door arms and to the hook at base of inner side panels Check operation of door and remove both springs Spring c...

Page 33: ... holes in the shim plate and door choke plate 12 To set the position of the door choke plate tape choke spacer S325 to the cavity base A and choke spacers S215 to the top and each side of the door choke B C D 13 Remove spacing pieces and check door operation T Mark Stage 1 Yellow are tightened at setup of choke green are tightened after initial setup and the remaining nuts are tightened in numeric...

Page 34: ...ly and fix around the LHS RHS top using 7 of M3x12 counter sunk screws around the LHS RHS and top of the door Squeeze skin onto door frame before tightening up screws to ensure snug fit See matrix below for door skin assembly to be used Grease up door arms where contact is made with roller PROCEDURE FOR BUILDING AND FITTING MEALSTREAM DOOR 5 Please note It is very important after completing this p...

Page 35: ...e figure 3 page 36 5 Visually inspect the vitreous enamel to ensure that it is undamaged Fitting a New Seal 1 Clip on end of the door seal in place Using a pair of long nose pliers stretch the door seal and connect the other end in place See figure 4 5 6 page 36 2 Visually inspect that the door seal is sitting in the rebate provided 3 Perform door interlock set up procedure See page 27 29 4 Perfor...

Page 36: ...Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 PROCEDURE FOR REPLACING DOOR SEAL ASSEMBLY 2 Please note It is very important after completing this procedure to do a Door interlock adjustment and test procedure See pages 27 29 ...

Page 37: ...M5 stainless steel dome nut Pt No 80X7025 Shelf runner Element cover plate 1 Loosen the rear fixings screws of both shelf runners with M6 nut runner 2 Remove the front fixings screws of both shelf runners with M6 nut runner 3 Pull the shelf runners forwards away from the rear screws 4 Remove the 4 off M5 dome nut securing the Element cover plate 5 Lift the Element cover plate out taking care to no...

Page 38: ... terminals at rear of oven 5 Remove M5 screw securing heater element 6 Remove heater element 7 Refit new heater element with new mesh washers fitted over each terminal and 3 off M5 Flat washer over the M5 screw this is very important to prevent microwave leakage 8 Tighten M5 screw and check that the heater element is not touching the cavity or protruding to much that it will not touch the element ...

Page 39: ...otor Earth tag then undo all securing nuts from the motor mounting plate and remove the fan motor assembly 7 Check the position and condition of the hot air motor damper seal this a important microwave leakage seal in the motor shaft screen See page 17 8 Fit new hot air motor assembly and fit all securing washers and nuts ensure it is aligned centrally into the hole in the cavity and tighten all s...

Page 40: ...er temperature stat on the magnetron and remove See figure 4 page 41 7 Visually inspect the new magnetron making sure that the wire mesh gasket seal is in place and undamaged Check the outer casing for any damage such as dents See figure 5 page 41 8 Attach the oven temperature stat to the new magnetron See figure 5 page 41 9 Visually inspect the magnetron mount in the wave guide making sure that i...

Page 41: ... Temperature Stat Screw Figure 1 Figure 3 4 x Magnetron screw fixings Figure 4 Screws Temperature Stat Figure 5 Figure 6 Wire mesh Magnetron mount Temperature Stat PROCEDURE FOR REPLACING MAGNETRON ASSEMBLY 2 Please note After completing this procedure do a microwave leakage test See page 22 23 ...

Page 42: ...e the Logic Assembly from the Control Panel Housing 3 Unplug the membrane tail from the Logic PCB Assembly 4 Using a D M M check for continuity between the correct terminals when the pads are pressed 5 When the panel has been tested re assemble and re test the control circuit 1 10 PROCEDURE FOR TESTING MEMBRANE PANEL CIRCUIT Mealstream 501 US ...

Page 43: ...Page 43 Mealstream 501 US Tim Hortons Unbranded Variant PROCEDURE FOR TESTING MEMBRANE PANEL CIRCUIT 2 Mealstream 501 US Tim Hortons French Canada Note PINS 1 4 Lower Layer Pins 5 10 upper layer Note PINS 1 4 Lower Layer Pins 5 10 upper layer ...

Page 44: ...Mealstream Ovens Pt No 32Z3403 Issue 16 Page 44 CIRCUIT DIAGRAM ALL MODELS ...

Page 45: ...ime has been set Invalid program has been set TIM HORTONS No cook program assigned to selected pad Set a time Set a valid time Use call back to check program Ensure correct Menukey is installed switch oven off then on to show key No 1 2 Oven not heating up Possible Heater fault Check heater fuse Confirm operation of heater circuit 1 Oven is not at correct temperature to start program Remove food A...

Page 46: ...rams In order to carry out the Power Test and Microwave Leakage Test on Tim Hortons variant Ovens the Icon Pad programs on the control panel need to be switched to Engineering Program Mode Engineering Mode does not affect the current Menukey program settings for the Icon pads and the current Menukey programs are automatically restored when the oven is next switched on To switch to Engineering Mode...

Page 47: ...splaying the following The Key Code The number of programs and each program number on the key When the display shows 0 00 the cavity lights up and the fans start Remove the key and close the cover and the oven is ready to use with the new programs EPS FAIL REDO If the key is removed before the download is complete or the process is interupted the display shows EPS then FAIL then REDO Switch oven o...

Page 48: ...e kȍ Standard Rate kȍ Max Rate kȍ 212 100 11 490 13 060 14 810 302 150 2 803 3 161 3 434 392 200 0 950 1 000 1 050 482 250 0 3572 0 3865 0 4171 350 177 1 741 R 200 C 1 kȍ 5 Temperature Sensor Resistance Note These resistances will only be apparent in a stable cavity temperature as the sensor has a slow response time ...

Page 49: ...ning the control panel and exterior surfaces 1 Remove the air filters from each side of the oven by sliding the filter out from the front 2 Wash in clean warm soapy water rinse and pat dry Slide back into position through slots Cleaning the oven cavity and door 1 Remove food particles from the gap between the rear baffle plate and the floor of the oven with a clean dry brush Location A Remove food...

Page 50: ...ler with Threaded nut fixing High speed motor Impeller with set screw fixing Rear view of oven showing Hot Air Motor If the oven has an impeller secured with a Threaded Nut it should be upgraded with Hot Air Motor Kit Part No 10C0192 The motor now has a plain shaft and the new impeller design is secured with a small hex set screw The RF trap motor shaft screen has a series of concentric grooves an...

Page 51: ... FLM020 10 30z1178 30A FUSE HOLDER 2 30Z1230 60HZ TRANS MULTI 208 220 240 1 790052 RED SILICON SEAL LH RH 3 metres 2571016 THERMAL CUT OUT 125C 2 10C0171 DOOR SPACER KIT 1 30Z1024 OVERHEAT SAFETY STAT 1 40C1141 DOOR SPRING LARGE MSTREAM 501 2 50E123 THERMISTOR 1 40C0949 HEATER ELEMENT 3 0 KW 208V 1 30Z1171 MAGNETRON PANASONIC 2M244 2 10C0192 M EALSTREAM 501 HOT AIR MOTOR 1 11C0412 MEMBRANE ON SUBS...

Page 52: ...ue 16 Page 52 APPENDIX 7 Door stop Adjustable microswitch bracket All Oven models from May 2005 No Description 208V 240V 126 Door arm stop assembly 11C0480 11C0480 127 Adj Microswitch support bracket 40C1233 40C1233 127 126 126 127 127 ...

Page 53: ...els from Serial No 144460505 May 2005 Switch oven off and isolate from mains supply prior to carrying out this modification 1 Remove the top cover and Left hand side panel When to perform this upgrade On inspection of the oven if the microswitch arm has been damaged by the door arm Ovens manufactured before Serial No 144460505 May 2005 2 Undo the 2 self tapping screws holding fuse bracket F5 F1 Sl...

Page 54: ...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 Mealstream Garland Description of error Suggestion for improvement to manual Please return this form to Garland Commercial Industries 1177 Kamato road Mississauga Ontario L4W 1X4 CANADA Attn Servic...

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