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Garland Mealstream - User Manual

Garland Mealstream
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Mealstream Ovens Pt. No. 32Z3403 Issue 15
Page 1
CAUTION MICROWAVE EMISSIONS
DO NOT BECOME EXPOSED TO EMISSIONS FROM THE MICROWAVE GENERATOR
OR PARTS CONDUCTING MICROWAVE ENERGY
Mealstream
SERVICE
SERVICE MANUAL
ALL CTM3 MODELS & TIM HORTON'S COMBINATION OVEN
MANUFACTURED FROM JANUARY 2003

Table of Contents

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Summary

Mealstream Service Manual

Microwave Safety

Warning to Service Technicians

Precautions for technicians to avoid microwave energy exposure during servicing.

Safety Checks Before Servicing

Checks for interlock, door closing, seals, hinges, and damage before activating the microwave source.

Checks Before Turning On Microwave Power

Inspecting magnetron, wave guide, and cavity for alignment and integrity.

Defective Component Handling

Repairing or replacing defective interlock, monitor, door seal, and generation systems.

Microwave Leakage Checks

Performing leakage checks per Federal or Canadian regulations.

Safety Code

Precautionary Advice

Recommends not attempting tasks if unsure, following safety code for servicing.

Pre-Servicing Checks

Checking for microwave emissions, continuous operation, and discharging HT capacitors.

Power Isolation

Instructions for switching off the mains supply or isolator switch before removing covers.

Post-Service Checks

Verifying electrical connections, insulation, interlocks, grounding, door operation, and temperature sensor.

Installation Instructions

Power Supply Requirements

Details electrical supply, breaker ratings, and hard-wiring requirements.

Principal Components - Top View

Magnetron and Resistor

Identifies the magnetron and a 470 Ohm resistor.

Microwave Leakage Test Procedure

Warning and Tool Requirements

Warns about safety and lists required tools for leakage testing.

Pre-Measurement Notes

Provides notes on meter calibration, range setting, probe handling, and measurement areas.

Leakage Test Procedure Steps

Outlines the step-by-step process for conducting the leakage test.

Microwave Leakage Test Procedure (Continued)

Leakage Reading Standards

Specifies acceptable leakage limits (4mW/cm²) and reporting requirements.

Measurement Points

Identifies specific areas on the oven for testing leakage with figures.

Power Output Measurement Procedure

Standard and Approximate Methods

Explains the standard and approximate methods for measuring power output.

Tim Hortons Ovens - Engineering Mode

Details how to switch Tim Hortons ovens to Engineering Mode for testing.

General Market Models - Test Steps

Provides steps for power output measurement on general models.

Tim Hortons Ovens - Test Steps

Provides steps for power output measurement on Tim Hortons models.

Temperature Rise Calculation

Explains how to calculate temperature rise and provides expected ranges.

Principal Components Test - Transformer

Required Tools and Warnings

Lists tools needed and provides safety warnings for transformer testing.

Transformer Winding Resistance Test

Details using a DMM to check resistance of mains, HV, and filament windings.

Transformer Insulation Resistance Test

Details using a Megger to test insulation resistance to chassis.

Principal Components Test - Capacitor and Rectifier

High Voltage Capacitor Test

Details testing HV capacitor continuity and insulation resistance.

High Voltage Rectifier Test

Details testing HV rectifier continuity in both directions.

Door Interlock Adjustment and Test

Microswitch Arrangement

Explains the "Primary, Secondary, and Monitor" microswitch setup.

Primary and Secondary Interlock Functions

Explains how primary and secondary switches control microwave emissions.

Door Interlock Adjustment and Test (Continued)

Pre-Test Safety Warning

Emphasizes disconnecting power and setting switch to OFF before testing.

Interlock Activation Sequence - Door Closing

Details the order of interlock switch activation when closing the door.

Interlock Activation Sequence - Door Opening

Details the order of interlock switch activation when opening the door.

Door Interlock Adjustment and Test (Step-by-Step)

Spacer Insertion Steps

Provides step-by-step instructions for inserting door spacers.

Building and Fitting the Mealstream Door

Building and Fitting the Mealstream Door (Steps 1-4)

Building and Fitting the Mealstream Door (Steps 5-8)

Building and Fitting the Mealstream Door (Steps 9-11)

Building and Fitting the Mealstream Door (Steps 12-13)

Replacing Door Seal Assembly

Removing Old Door Seal

Provides steps for unclipping and removing the existing door seal.

Fitting New Door Seal

Details steps for clipping, stretching, and securing the new door seal.

Post-Seal Replacement Procedures

Stresses performing interlock setup and leakage test after seal replacement.

Replacing Door Seal Assembly (Figures)

Post-Procedure Note

Reminds to perform door interlock adjustment and test.

Replacing the Heater Element

Element Replacement Steps

Details disconnecting, removing, and refitting the heater element.

Important Refitting Notes

Highlights using mesh/flat washers to prevent microwave leakage.

Post-Replacement Checks

Emphasizes performing leakage test and checking element fit.

Replacing the Hot Air Motor Assembly

Post-Replacement Checks

Emphasizes performing leakage test around the motor assembly.

Replacing the Magnetron Assembly

Parts, Tools, and Warnings

Lists magnetron part, tools, and safety warnings for replacement.

Magnetron Removal Steps

Details removing casing, duct plate, wiring, and the magnetron itself.

New Magnetron Preparation

Instructions for inspecting and attaching the temperature stat to the new magnetron.

Magnetron Installation Steps

Details positioning and fixing the new magnetron, reconnecting wiring.

Replacing the Magnetron Assembly (Figures)

Figures 1-3: Removal Illustrations

Illustrates magnetron removal steps (screws, fixings).

Figures 4-6: Installation Illustrations

Illustrates magnetron installation steps (stat, wire mesh, mount).

Post-Procedure Note

Reminds to perform a microwave leakage test.

Testing Membrane Panel Circuit

Testing Membrane Panel Circuit (Variants)

Circuit Diagram - Models Before 05.28.02

Circuit Diagram - Models 05.28.02 to 11.10.02

Circuit Diagram - Models After 11.11.02

Circuit Diagram - Models After 04.06.03

Error Codes and Diagnostics

Error Code E1

Describes E1 error (door shut, electrical fault, magnetron overheating) and solutions.

Error Code E3

Describes E3 error (invalid time/program, no cook program) and solutions.

Error Code E4

Describes E4 error (oven not heating, heater fault) and solutions.

Error Code E5

Describes E5 error (cavity overheating) and solutions.

Error Code E6

Describes E6 error (incorrect temperature) and solutions.

EPS-FAIL-REDO Error

Explains error during MenuKey download and how to resolve it.

Appendix 1: Tim Hortons Test Procedures

Engineering Mode Programs

Explains how to switch Tim Hortons ovens to Engineering Mode for testing.

Power Test and Leakage Check

Details using Program Pad 01 for power test and leakage check.

Appendix 2: MenuKey Download Procedure

Changing Menus on the Oven

Step-by-step guide to changing cooking programs using MenuKey.

EPS-FAIL-REDO Explanation

Explains the EPS-FAIL-REDO error during download.

Summary

Mealstream Service Manual

Microwave Safety

Warning to Service Technicians

Precautions for technicians to avoid microwave energy exposure during servicing.

Safety Checks Before Servicing

Checks for interlock, door closing, seals, hinges, and damage before activating the microwave source.

Checks Before Turning On Microwave Power

Inspecting magnetron, wave guide, and cavity for alignment and integrity.

Defective Component Handling

Repairing or replacing defective interlock, monitor, door seal, and generation systems.

Microwave Leakage Checks

Performing leakage checks per Federal or Canadian regulations.

Safety Code

Precautionary Advice

Recommends not attempting tasks if unsure, following safety code for servicing.

Pre-Servicing Checks

Checking for microwave emissions, continuous operation, and discharging HT capacitors.

Power Isolation

Instructions for switching off the mains supply or isolator switch before removing covers.

Post-Service Checks

Verifying electrical connections, insulation, interlocks, grounding, door operation, and temperature sensor.

Installation Instructions

Power Supply Requirements

Details electrical supply, breaker ratings, and hard-wiring requirements.

Principal Components - Top View

Magnetron and Resistor

Identifies the magnetron and a 470 Ohm resistor.

Microwave Leakage Test Procedure

Warning and Tool Requirements

Warns about safety and lists required tools for leakage testing.

Pre-Measurement Notes

Provides notes on meter calibration, range setting, probe handling, and measurement areas.

Leakage Test Procedure Steps

Outlines the step-by-step process for conducting the leakage test.

Microwave Leakage Test Procedure (Continued)

Leakage Reading Standards

Specifies acceptable leakage limits (4mW/cm²) and reporting requirements.

Measurement Points

Identifies specific areas on the oven for testing leakage with figures.

Power Output Measurement Procedure

Standard and Approximate Methods

Explains the standard and approximate methods for measuring power output.

Tim Hortons Ovens - Engineering Mode

Details how to switch Tim Hortons ovens to Engineering Mode for testing.

General Market Models - Test Steps

Provides steps for power output measurement on general models.

Tim Hortons Ovens - Test Steps

Provides steps for power output measurement on Tim Hortons models.

Temperature Rise Calculation

Explains how to calculate temperature rise and provides expected ranges.

Principal Components Test - Transformer

Required Tools and Warnings

Lists tools needed and provides safety warnings for transformer testing.

Transformer Winding Resistance Test

Details using a DMM to check resistance of mains, HV, and filament windings.

Transformer Insulation Resistance Test

Details using a Megger to test insulation resistance to chassis.

Principal Components Test - Capacitor and Rectifier

High Voltage Capacitor Test

Details testing HV capacitor continuity and insulation resistance.

High Voltage Rectifier Test

Details testing HV rectifier continuity in both directions.

Door Interlock Adjustment and Test

Microswitch Arrangement

Explains the "Primary, Secondary, and Monitor" microswitch setup.

Primary and Secondary Interlock Functions

Explains how primary and secondary switches control microwave emissions.

Door Interlock Adjustment and Test (Continued)

Pre-Test Safety Warning

Emphasizes disconnecting power and setting switch to OFF before testing.

Interlock Activation Sequence - Door Closing

Details the order of interlock switch activation when closing the door.

Interlock Activation Sequence - Door Opening

Details the order of interlock switch activation when opening the door.

Door Interlock Adjustment and Test (Step-by-Step)

Spacer Insertion Steps

Provides step-by-step instructions for inserting door spacers.

Building and Fitting the Mealstream Door

Building and Fitting the Mealstream Door (Steps 1-4)

Building and Fitting the Mealstream Door (Steps 5-8)

Building and Fitting the Mealstream Door (Steps 9-11)

Building and Fitting the Mealstream Door (Steps 12-13)

Replacing Door Seal Assembly

Removing Old Door Seal

Provides steps for unclipping and removing the existing door seal.

Fitting New Door Seal

Details steps for clipping, stretching, and securing the new door seal.

Post-Seal Replacement Procedures

Stresses performing interlock setup and leakage test after seal replacement.

Replacing Door Seal Assembly (Figures)

Post-Procedure Note

Reminds to perform door interlock adjustment and test.

Replacing the Heater Element

Element Replacement Steps

Details disconnecting, removing, and refitting the heater element.

Important Refitting Notes

Highlights using mesh/flat washers to prevent microwave leakage.

Post-Replacement Checks

Emphasizes performing leakage test and checking element fit.

Replacing the Hot Air Motor Assembly

Post-Replacement Checks

Emphasizes performing leakage test around the motor assembly.

Replacing the Magnetron Assembly

Parts, Tools, and Warnings

Lists magnetron part, tools, and safety warnings for replacement.

Magnetron Removal Steps

Details removing casing, duct plate, wiring, and the magnetron itself.

New Magnetron Preparation

Instructions for inspecting and attaching the temperature stat to the new magnetron.

Magnetron Installation Steps

Details positioning and fixing the new magnetron, reconnecting wiring.

Replacing the Magnetron Assembly (Figures)

Figures 1-3: Removal Illustrations

Illustrates magnetron removal steps (screws, fixings).

Figures 4-6: Installation Illustrations

Illustrates magnetron installation steps (stat, wire mesh, mount).

Post-Procedure Note

Reminds to perform a microwave leakage test.

Testing Membrane Panel Circuit

Testing Membrane Panel Circuit (Variants)

Circuit Diagram - Models Before 05.28.02

Circuit Diagram - Models 05.28.02 to 11.10.02

Circuit Diagram - Models After 11.11.02

Circuit Diagram - Models After 04.06.03

Error Codes and Diagnostics

Error Code E1

Describes E1 error (door shut, electrical fault, magnetron overheating) and solutions.

Error Code E3

Describes E3 error (invalid time/program, no cook program) and solutions.

Error Code E4

Describes E4 error (oven not heating, heater fault) and solutions.

Error Code E5

Describes E5 error (cavity overheating) and solutions.

Error Code E6

Describes E6 error (incorrect temperature) and solutions.

EPS-FAIL-REDO Error

Explains error during MenuKey download and how to resolve it.

Appendix 1: Tim Hortons Test Procedures

Engineering Mode Programs

Explains how to switch Tim Hortons ovens to Engineering Mode for testing.

Power Test and Leakage Check

Details using Program Pad 01 for power test and leakage check.

Appendix 2: MenuKey Download Procedure

Changing Menus on the Oven

Step-by-step guide to changing cooking programs using MenuKey.

EPS-FAIL-REDO Explanation

Explains the EPS-FAIL-REDO error during download.

Garland Mealstream Specifications

General IconGeneral
BrandGarland
ModelMealstream
CategoryOven
LanguageEnglish

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