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Rev B - i5 Service Manual.qxp

1. FAN1 COOLING COMPARTMENT ITURBOCHEF TECHNICAL SUPPORT 800 908 8726 USA 214 379 6000 International w MW2 CT A 230VAC 20 4 WIRE INPUT oo 380 415 30 5 WIRE INPUT r 10 2a0vac BMSC E VAC IN 240vac Analog Speed0 10V 3 PHASE VO COMMON fi Sur ENABLE 1 0 COM STATUS OK UO COMMON A 18 RED MAG B 7 BLACK er B 1 WHITE SPLICE 1 0 10V VO COMMON 3 PHASE ENABLE 1 0 COM STATUS OK VO COMMON AAT RED 8 BLACK 2 WHITE 8 BLACK 10 GRAY 180 240 B 7 BLACK NOTE NOT CONNECTED FOR INTERNATIONAL MARKETS VOLTAGE a E 1 BLACK E2 RED MODULE j K8 STIRRER A B 1 i rA 3 9 Se 2 K7 FANS UMPER ONLY FOR SINGLE PHASE Zu C 1 GRAY u H in oi e 8220 EMI FILTER FOR UK VERSION 1 208 STIRRER REVISIONS DESCRIPTION RELEASE FOR PRODUCTION COLOR CODE LOW CONTROL VOLTAGE BK BLACK 24 VDC COMMON OR ORANGE STATUS INPUT WH WHITE CONTROL OUTPUT RD RED 24VDC NOTE ALL 50 HZ OVENS HAVE 230VA
2. Is the oven rack posi tioned correctly upper vs lower position NO Y YES Y Place the oven rack in correct position Is the correct amount of food portion being cooked NO Y YES Y Ensure that the correct amount is being Is the food item being prepared correctly and consistently For example bread cuts revision correct Verify with cooked not more or customer or contact TurboChef Customer Service less than the recipe specifies 1 are straight and not V cuts meat is sliced at correct thickness pizza dough is correct consistency etc YES Does the problem occur EVERY time the food item is cooked He NO Replace the control board page A 8 Troubleshoot the fault s using the steps on pages 37 44 YES Are there any fault codes present See page Ensure that the food item is properly prepared 47 DNILOOHSFIANOUL 48 TROUBLESHOOTING Troubleshooting Read Fail Message When Loading Menu i Smart Card 4 Does a backup copy of the menu work NO Did you use a smart card or USB device Is the connection from smart card reader to control board OK YES NO H No backup copy USB Device u Is the file named correctly menudata bin and in
3. If not clear faults transformers page 30 Are the high voltage transformers functioning properly Did fault repeat Ge YES Y Replace the HV transformers s See page A 7 through A 8 y Test the filament transformers page 30 Are the filament trans formers functioning properly Replace the filament transformers s See page A 7 through A 8 Replace the capacitor s See page A 7 through A 8 NO Test the capacitors page 29 gt Test the high voltage diodes page 30 Are the diodes functioning properly NO Y Replace the diode s See page A 7 through A 8 Test the magnetron for an open shorted filament page 32 Are the filaments functioning properly NO YES Y Y YES Replace the magnetron s See page A 12 through A 13 Replace the control board See page A 8 Are the capacitors functioning properly 41 DNILOOHSFIANOUL 42 TROUBLESHOOTING Troubleshooting F4 MONITOR Door Monitor Defective NO Is the F3 or F4 fuse blown I YES gt Replace the F3 or F4 j fuse see page A 5 through A 6 Are the switches open Ly ing in the correct sequence P S M To access TEST MODE or for info on status indicators NO see page 15 R
4. 406 mm Volume 2 22 ft 63 liters Clearances Top 16 406 mm Sides 2 51 mm Oven Construction Exterior Two tone stainless steel front top and sides 304 stainless steel removable grease pan Ergonomic door handle Rubber seal for surface mounting Side handles for lifting Interior 304 stainless steel interior Fully insulated cook chamber Removable rack with dual setting option Top and bottom jetplates l 00 GA ery C ll NOILVTIVLSNI ANY SNOILLVDIAID34S SPECIFICATIONS AND INSTALLATION Electrical Specifications TurboChef recommends a Type D circuit breaker for all installations outside the US Single Phase i5 US model i5 9500 1 Voltage 208 240 VAC Frequency 60 Hz Current 48 amps Max Input 9500 11500 watts Plug NEMA 6 50P i5 UK model i5 9500 2 UK Voltage 230 VAC Frequency 50 Hz Current 48 amps Max Input 10000 watts Plug IEC 309 3 pin i5 BK model i5 9500 6 BK Voltage 220 VAC Frequency 60 Hz Current 48 amps Max Input 10000 watts Plug IEC 309 3 pin i5 LA model i5 9500 7 LA Voltage 220 VAC Frequency 60 Hz Current 48 amps Max Input 10000 watts Plug NEMA 6 50P i5 JK model i5 9500 8 JK 50 Hz i5 9500 10 JK 60 Hz Voltage 200 VAC Frequency 50 or 60 Hz Current 46 amps Max Input 9000 watts Plug PSE marked 3 blade North America models include a voltage sensor which detects 208 or 240 VAC
5. Magnetron cooling fans Power supply Stirrer motor The F3 fuse is designed to blow in case of an over current situation relative to the left microwave system magnetron high voltage transformer diode capacitor The F4 fuse is designed to blow in case of an over current situation relative to the right microwave system magnetron high voltage transformer SWALSAS NJAO diode capacitor OVEN SYSTEMS High Limit Thermostat The high limit thermostat is a 250 VAC 3 pole manual reset thermostat with a trip point of 572 F 300 C The thermostat interrupts power to the main convection heater in the event of an abnormal condition Reset the high limit thermostat by pressing the reset button Figure 31 Reset Button Figure 31 High Limit Reset Button Keypad The keypad is a 7 x 10 matrix membrane switch For details on key functions see page 9 Magnetron Cooling Fans The magnetron cooling fans supply air to the magnetrons and are actuated by the K7 relay They operate at 208 240 VAC 60 Hz installations with voltage sensing 220 VAC 60 Hz installations with no voltage sensing 230 VAC 50 Hz installations 200 VAC Japan installations Magnetron Thermostats The magnetron thermostats are open on rise They are designed to open at 212 F 100 C which triggers an F5 fault NOTE The magnetron thermostats are wired in series
6. Lifting and Placing the Oven A A A WARNING Oven weighs approximately 275 lbs 125 kg Never lift with fewer than two people WARNING Lift only using the provided hand grips Never lift the oven by the door handle or by its base WARNING The oven must be properly placed on a table or countertop at all times TurboChef will not recognize a fallen oven as a warrantable claim and is not liable for any injuries that may result N WARNING This oven is not intended for 5 built in installation i e installing the oven in any structure that surrounds the oven by five or more sides Be sure to provide a minimum of 2 51 mm clearance for all sides and 16 406 mm clearance for the top Position one or more persons at the front and rear of the oven Place hands into grips see Figure 2 and lift Place the oven on a surface that is at least 30 762 mm deep and capable of supporting 280 lbs 127 kg If installing onto an oven cart make sure the wheels casters are locked Install the oven rack or other provided cooking surface Plug in the oven A NOTE The oven is primarily serviced through its top DO NOT install shelving directly over the unit The operator will be responsible for service charges incurred as a result of added time required to access the top of the oven NOILYTIYLSNI ANY SNOLLVDIAID34S SPECIFICATIONS AND INSTALLATION Installation Near Open Heat Source See Figure 4 page 5
7. OVEN TCC 244F SET POINT 500F BS WARMING UP 08 00 OVENTCC 500F 01 17 SET POINT 500F Figure 7 Standard Operation Modes Cooking This section explains how to cook a food product by describing the standard operation modes through which the oven progresses The oven is preprogrammed with recipe settings at the time of manufacture and is ready to operate out of the box If these settings are erased new menu settings must be either loaded via smart card USB drive page 17 or programmed manually pages 19 21 The oven will not cook unless settings are present Note that modes are not always sequential as shown in Figure 7 above Typically modes 5 9 will be repeated before cooling the oven mode 10 COOKING COOKING DONE PLEASE REMOVE FOOD FROM OVEN RECIPE 6 ADDITIONAL COOKING OPTIONS RECIPE 7 COOK MORE RECIPE 8 BROWN MORE RECIPE 9 COOK AND BROWN MORE RECIPE 10 SAVE ADJUSTED TIME COOLING DOWN PLEASE OPEN OVEN DOOR 288F START COOK mm eee ewei See er ses MODE 1 Oven Off MODE 2 Temperature Select if applicable MODE 3 Warming Up MODE 4 Soak MODE 5 Ready to Cook or Idle MODE 6 Adjust Time if enabled MODE 7 Cooking MODE 8 Remove Food from Oven MODE 9 Cook More if enabled MODE 10 Cooling Down Mode 1 Oven Off Mode during which all cooking components are off and the oven temperature has receded below 150 F 66 C but the display a
8. TURBO CHEF Accelerating the World of Cooking Service Manual FOR THE TURBOCHEF i5 RAPID COOK OVEN For further information call 800 90TURBO or 1 214 379 6000 The information contained in this manual is important for the proper installation use maintenance and repair of this oven Follow these procedures and instructions to help ensure satisfactory baking results and years of trouble free service Errors descriptive typographic or pictorial are subject to correction Specifications are subject to change without notice Please carefully read this manual and retain it for future reference Table of Contents Safety Instructions General Safety Information Reducing Fire Risk Grounding Instructions Power Cord Replacement Precautions to be Observed Before and During Servicing to Avoid Possible Exposure to Excessive Microwave Energy RF Interference Considerations Specifications and Installation Theory of Operation Certifications Dimensions Oven Construction Electrical Specifications Unpacking Instructions Lifting and Placing the Oven Installation Near Open Heat Source Optional Installation Items Voltage Selection Daily Maintenance Oven Controls and Cooking Oven Controls Cooking Mode 1 Oven Off Mode 2 Temperature Select Mode 3 Warming Up Mode 4 Soak Mode 5 Ready to Cook or Idle Mode 6 Adjust Time Mode 7 Cooking Mode 8 Remove Food from Oven Mode 9 Cook More
9. pages A 7 through A 8 Troubleshooting F6 EC TEMP Electrical Compartment Temperature High YES Is the oven in an area of moderate Does the oven have room to ventilate Required clearances Top 16 406 mm Sides 2 51 mm NO YES i Are both cooling fans rotating YES j Check for obstructions in the airflow and remove them and clean the filter temperature 120 F 49 C or cooler NO Relocate oven to Move oven to open area or remove items that are in close proximity cooler area Is the wire harness properly connected Check cooling fan thermostat and cooling fans H NO See page 51 for schematic NO YES y Replace defective component see page A 7 through A 8 Correct wiring Troubleshooting F7 THERMO RTD Open Is the RTD open Using an Ohm Meter measure at the control board RTD should meas ure approximately 109 Ohms at 75 F 24 C la YES 4 Is the RTD properly connected to the control board See page 51 for schematic NO gt Correct connection YES Replace the RTD page A 11 MO Replace I O Control Board page A 8 43 DNILOOHSFIANOUL 44 TROUBLESHOOTING Tro
10. screen page 14 To load a menu to the oven 1 Insert the source smart card or USB see Figure 21 page 18 N Press the L1 soft key to load from a smart card or the L4 soft key to load from USB Figure 19 3 Verify the oven beeps and reads FINISHED Figure 20 NOTE To successfully load a menu from USB The menu file must be a binary BIN file The menu file name must be MENUDATA BIN The menu file must exist in a top level folder i e the folder cannot be a sub folder of any other folder on the USB device The folder name must be TC_MENUS To save a copy of a menu from the oven 1 Insert the source smart card or USB see Figure 21 page 18 N Press the L2 soft key to save to a smart card or the L5 soft key to save to USB Figure 19 3 Verify the oven beeps and reads FINISHED NOTE To successfully save a menu to USB The USB device must contain a top level folder titled TC_MENUS LOAD FROM CARD FINISHED SAVE TO CARD LOAD FROM USB SAVE TO USB AGOW OJNI Figure 20 Loading Finished 18 INFO MODE Updating the Software From the Oven Off screen 1 Insert the smart card see Figure 21 If multiple smart cards are required ensure the correct smart card is loaded first From the COOLING DOWN or OVEN OFF mode press and hold the Info key until the oven resets approximately 5 seconds When the oven beeps one long high tone the loa
11. Cooling Down Oven Off screen 3 Display The display shows information relevant to the current oven operation and or user options 4 Soft Keys There are ten soft keys five to the left L1 thru L5 where L1 top and right R1 thru R5 where R1 top of the display Press a soft key to select an option adjacent to that key on the display 5 Back Stop Key When the oven is cooking press the Back Stop key to immediately terminate a cook cycle When the oven is in the IDLE MODE see page 11 MODE 5 or the INFO MODE see page 13 press to return to the previous screen 6 Up and Down Keys When the oven is ready to cook i e warmed up and waiting for a cook command press the Up or Down key to view additional food groups if applicable When the oven is in the INFO MODE see page 13 press to navigate between and within screens 7 Enter Key Press the Enter key to confirm a selection where applicable 8 Numeric Keypad Use the numeric keypad to program the oven or modify cook settings The numeric keypad also contains a Back Stop key and an Enter key which are functionally identical to Items 5 and 7 above ONIMOOD ANY S1OY LNOD NJAO 10 OVEN CONTROLS AND COOKING a AO GROUP 1 OVEN OFF GROUP 2 READY TO CLEAN GROUP 3 SETPOINT 500F GROUP 4 GROUP 5 SELECT COOK TEMPERATURE RECIPE 1 RECIPE 2 GROUP 1 RECIPE 3 RECIPE 4 RECIPES WARMING UP ADJUSTTIME
12. Fault Code Descriptions For instructions on viewing the fault counter see page 13 F1 Blower Running Status Bad This fault is displayed when the motor controller indicates no running status The motors and motor controller are monitored continuously in all modes with special handling in the TEST MODE see page 15 If a fault is detected the control will terminate a cook cycle and display F1 Blower Upon turning on the oven the control will attempt to restart the motors If the restart of both motors is successful the fault code will be cleared from the display The fault is also cleared from the display at the onset of cooking or when a blower motor is tested in TEST MODE F2 Cook Temperature Low This fault is displayed if the cook cavity temperature is more than 84 F 47 C below the set temperature after five seconds into a cook cycle The fault is cleared from the display at the onset of cooking if the cook cavity temperature is within 84 F 47 C of the set temperature or when the heater is tested in TEST MODE see page 15 F3 Magnetron Current Low This fault is displayed when the current transformer CT on the I O control board detects less than 10 amps The fault is monitored when the microwave is on during a cook cycle or in TEST MODE The fault is cleared from the display at the onset of a cook cycle if the CT detects 10 amps or when the magnetrons are successfully energized in TEST MODE
13. LINE V 208 240 BR BROWN LINE V 208 240 COLOR CODE HIGH VOLTAGE TENSION WH HI VOLTAGE WIRE FOR MAG 1 BK HI VOLTAGE WIRE FOR MAG 2 OR 240 LINE INPUT FOR TAP 3 ON TRANSFORMERS BK HI TEMP 240 VAC WIRE SAFETY INTERLOCKS a KEYPAD MONITOR SWITCH C SECONDARY INTERLOCK See A 20 PIN DE E HR A18 TOP BLOWER 0 10 VDC RED A17 BOT BLOWER 0 10 VDC RED AQ RTD 1 INPUT ORANGE A8 RTD 2 INPUT ORANGE A7 RTD 3 INPUT RED A5 VOLTAGE MODULE GROUND BLACK B17 K1 A 24 VDC OUTPUT RED B16 K8 B STIRRER WHITE B10 BOT BMSC STATUS J1 5 GRAY B8 BOT BMSC GND J1 2 84 BLACK B7 TOP BMSC GND J2 2 84 BLACK B2 BOT BLOWER ENABLE J1 3 WHITE B1 TOP BLOWER ENABLE J2 3 WHITE C22 K5 B4 HEATERYWHITE C21 K4 A2 HEATERYWHITE C20 SPEAKER RED C19 24 VDC INPUT RED C17 MAG OT 24VDC RED C16 K7 B MAGNETRON FANSYWHITE C14 K2 B MAGNETRONS WHITE C13 K1 B FILAMENT TRANSFORMERS WHITE C12 K2 A MAG OT STATUS WHITE C11 K3 B MONITOR STATUS ORANGE C10 CDP N O STATUSNHITE C9 CDS N O STATUSWHITE C8 24 VDC INPUT BLACK C7 SPEAKER GROUND BLACK C6 CDP C GROUND BLACK C5 CDM C 8 CDS C GROUNDYBLACK C4 K6 B VOLTAGE SELECTOR WHITE C3 VOLTAGE SELECTOR INPUT RED C1 TOP BMSC STATUS GRAY
14. To Replace This First Remove This Item Part Number No DUN Es Top ER oo GE GE ENER Page A7 page A ai UE AT page A 9 Page A 11 Vers Blower Motor Bottom 15 9042 Vv EMI Filter EMI Fil Brkt Blower Motor Top 15 9040 vw EMI Filter EMI Fil Brkt Blower Wheel Bottom 103550 Vv Blower Motors Blower Wheel Top 103551 Vv Blower Motors Capacitor High Voltage 100232 v Capacitor Clamps Capacitor Clamp 100134 v Catalytic Converter 15 9066 v RTD and Heater Assy Control Board CON 7002 v Cooling Fan Exterior TC3 0433 vw ee a Brkt Finger Cooling Fan Interior TC3 0433 Vv Cooling Fan Finger Guard 100086 vw Filter Filter Bracket Cooling Fan Magnetron 100083 Vv Cooling Fan Magnetron Bracket 15 9263 Vv Diodes High Voltage 100481 vw Display 103360 Vv Door Assembly 15 9308 v Door Gasket 15 9309 v Shunt Plate Door Handle 15 9253 Vv Door Skin Door Skin 15 9109 v Door Drain Pan 15 9252 vw EMI Filter 100546 Vv EMI Filter Bracket 15 9257 v Filter Air 15 9039 v Filter Bracket 15 9060 Vv Fuse F1 12 amp 100592 Vv Fuse F2 12 amp 100592 Vv Fuse F3 12 amp 100592 v Fuse F4 12 amp 100592 vw Fuse Holder 103548 Vv Fuses Hand Grip 15 9256 Vv Heat Shield Support Bracket 15 9224 Vv Heat Slinger 102708 vw Blower Motors Heater Assembly 15 9284 vw RTD Helper Spring Interlock Switch Left 103599 Vv Helper Spring Interlock Switch Right 103599 Vv Hinge Bracket Slide LHS 15 9196 v vw Door Switches
15. 12 Warm up the oven allowing the additional 8 minute soak to achieve thermal equilibrium in the cook cavity 13 If necessary adjust the oven door by ensuring it is parallel to the frame See page 24 14 Adjust the door switches to ensure the proper sequence adjacent 15 Test for microwave leakage page 27 Step 5 Loosen Step 7 Tighten Step 8 Loosen Slightly Step 4 Step 3 A Figure 27 Counter Balance Adjustment Measuring RF Leakage for Microwave Safety WARNING Procedure requires work while the oven and water loads are hot As a result exercise extreme caution when testing An RF microwave leakage test must be performed at the conclusion of the following service tasks Door removal replacement and or adjustment Wave guide removal and or replacement Magnetron removal and or replacement Door gasket WARNING If the unit fails the microwave leakage test leakage greater than 5m W cm the oven must be taken out of service immediately until the defect is corrected In addition the CDRH Regulation 21 Subpart C 1002 20 requires that leak age readings of over 5SmW cm must be reported to the manufacturer Step 6 Notch should rest against side of bracket Step 6 Thin side of spacer fits between screw and bracket Step 4 Step 3 To measure RF leakage 1 Place the oven in WARMING UP MODE page 11 and allow it to warm up to the set temperature approximately 15 m
16. 8 32 x 2 1 2 Lg PPHD SS 101661 qty 2 6 Cooling Fan Finger Guard 100086 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 2 7 Cooling Fan Magnetron 100083 B Washer Lock 10 Int Tooth Cres 3102290 ety 3 8 Cooling Fan Magnetron Bracket 115 9263 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 4 9 Diode High Voltage 100481 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 2 10 Display 103360 Nut Keps Hex 4 40 Ext Tooth 102960 qty 4 11 Motor Controller 100446 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 4 a Sept komm HE 122500275 15D a 13 Stirrer Hub 104132 Set Screw Provided N A 14 Stirrer Motor 15 9025 Screw M4 x 0 7 x 8 PPHD Int Tooth SS 101672 qty 2 15 Stirrer Motor Bracket 15 9075 Screw M4 x 0 7 x 8 PPHD Int Tooth SS 101672 qty 2 16 Stirrer Shaft 15 9151 None None 17 Thermocouple EC 700 1199 None None 18 Thermostat Cooling Fans 102086 Screw 6 x 1 2 PPHD Drill Point SS 101687 qty 2 19 Thermostat High Limit 102075 Screw M4 x 0 7 x 8 PPHD Int Tooth SS 101672 qty 2 20 Transformers Filament NGC 3061 1 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 4 21 Transformers High Voltage NGC 3062 1 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 4 Replacing Items Removing Left Side Cover Required Figures A 7 A 8 A DANGER Before replacing any oven component ensure the oven is removed from any power source Replacing a component while the oven is plugged in can result in serious
17. Heater Speaker USB port Voltage sensor Wire harness Control Board The control board controls each electrical compo nent of the oven See page 51 for a schematic 24 VDC can be measured at pin 2 of the J7 connector Display The vacuum fluorescent display is the primary user interface Electrical Compartment Cooling Fans The cooling fans located in the rear of the oven are actuated by the cooling fan thermostat when the temperature of the electrical compartment reaches 120 F 49 C Electrical Compartment Cooling Fan Thermostat The cooling fan thermostat actuates the rear cooling fans when the electrical compartment temperature reaches 120 F 49 C Electrical Compartment Thermocouple The electrical compartment thermocouple is a type K thermocouple which measures the temperature of the electrical compartment If the temperature of the electrical compartment is above 158 F 70 C an F6 EC TEMP fault will display The control board checks the temperature of the electrical compartment once every 60 seconds EMI Filter The EMI filter helps suppress the amount of RF interference emitted by the oven Fuses All four fuses are 12 amp class CC The Fl fuse via blue wire or F2 fuse via brown wire is designed to blow in case of an over current situation relative to the following components BMSC motor controller Electrical compartment cooling fans Filament transformers
18. NM CAUTION Before removing installing any component make sure it is disconnected from the wire harness where applicable A NOTE Hardware listed is required for installing component to oven To remove the top cover 1 Open the top cover see page A 5 for instructions 2 Remove the hinge screws located near the back of each side of the top cover 3 Detach the support braces from the oven frame The should remain attached to the top panel CAUTION When detaching the support braces be sure to support the top cover to prevent it from collapsing onto the components in the electrical compartment 4 Remove the top panel and place it somewhere safe N CAUTION The top cover has critical components attached Handle it carefully Figure A 4 Removing Top Cover Required Figure A 5 Stirrer Motor and Assembly Detail A 7 SLNINO4IWOD NAO DNIDV 1434 XIGNAddV A 8 APPENDIX REPLACING OVEN COMPONENTS Figure A 6 Top Cover Detail eee Item Description Item Part Number Hardware Description Hardware Part Number s 1 Capacitor High Voltage 100232 None None 2 Capacitor Clamps 100134 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 2 3 Control Board CON 7002 Nut Keps Hex 6 32 Ext Tooth Cres 102961 qty 4 4 Cooling Fan Exterior TC3 0433 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 2 5 Cooling Fan Interior TC3 0433 Screw
19. When placing a TurboChef oven near an open heat source strictly adhere to the following If the oven is being placed near a grill or stove a divider must exist between the oven and the open heat source with a minimum of 6 152 mm between the oven and the divider If the oven is being placed near a fryer a divider must exist between the oven and fryer with a minimum of 12 305 mm between the oven and the divider The height of the divider must be greater than or equal to the height of the oven 24 3 or 618 mm Verify oven location has a minimum 16 406 mm clearance on top and minimum 2 51 mm of clearance on each side Optional Installation Items See Figure 5 page 5 TurboChef Oven Cart Part Number NGC 1217 3 Height 32 813 mm Width 27 8 706 mm Depth 26 625 676 mm Oven Restraint Kit Part Number TC3 0242 WARNING The Oven Restraint Kit will not prevent the oven from falling off a countertop if the oven is pulled off or allowed to slide off the edge Installation instructions are included with the kit ChefComm Pro ChefComm Pro is a PC program for developing and maintaining menus and recipes To purchase ChefComm Pro and a card reader contact customer service at 800 90TURBO or 1 214 379 6000 Voltage Selection For North America oven models the oven will detect 208 or 240 incoming voltage The initial voltage selection is typically completed befo
20. F4 Door Monitor Defective This fault is displayed when the control detects that the monitor interlock switch unlatches before the primary or secondary interlock switches In addition this fault will blow the F3 and F4 fuse if the microwave high voltage system is energized when the fault occurs The fault is cleared from the display when the oven is powered off and then back on NOTE Door interlock switches are in parallel See the oven schematic page 51 The fault is monitored during a cook cycle and in TEST MODE when the microwave is on F5 Magnetron Over Temperature This fault is displayed when either magnetron thermostat reaches 212 F 100 C The thermostats will reset automatically and are wired in series The fault is cleared from the display at the onset of a cook cycle if the thermostat is closed or when the magnetrons are successfully tested in TEST MODE F6 Electrical Compartment Temperature High This fault is displayed when the EC thermocouple exceeds 158 F 70 C The EC temperature is monitored once per minute The fault is cleared from the display if on the next check the EC thermocouple temperature is below the indicated limit DNILOOHSFIANOUL 38 TROUBLESHOOTING F7 RTD Open This fault is displayed when the control detects that the RTD is open The display will show a reading of 999 F C indicating the RTD is open The fault is cleared when the control detects continuity F
21. Hinge Bracket Slide RHS 15 9195 Vv Vv Door Switches Hinge Cam Weldment LHS 15 9313 v Vv Door Switches Hinge Cam Weldment RHS 15 9314 v vw Door Switches See page A 12 through A 13 for removing door hinge components magnetrons magnetron thermostats or waveguides A 1 SININOdWO NAO DNIDV 1434 XIGNAddV A 2 APPENDIX REPLACING OVEN COMPONENTS Hinge Guide Switch Slide Lower 15 9316 vw v Door Switches Hinge Guide Switch Slide Upper 15 9315 v v Door Switches Hinge Gusset LHS 15 9178 v v Door Switches Hinge Gusset RHS 15 9179 v v Door Switches Hinge Module Base 15 9193 vw vw Door Switches Hinge Torsion Bar 15 9144 wi vw Door Switches Hinge Weldment Countrbince Bracket LHS 15 9326 D v Door Switches Hinge Weldment Countrblnce Bracket RHS 15 9327 vw v Door Switches Interlock Switch Monitor 102012 vw Interlock Switch Primary 102012 vw Interlock Switch Secondary 102012 v Jetplate Bottom 15 9159 v Rack Jetplate Top 15 9203 v Keypad 15 9247 v Lower Front Panel 15 9246 Vv Drain Pan Magnetron Left NGC 3015 D D Magnetron Right NGC 3015 D v Motor Controller 100446 v Power Cord 15 9127 vw Power Supply 101211 Vv Pwr Supply Brkt Power Supply Bracket 15 9280 v Rack 15 9168 v Rack Support 15 9165 v Rack Relay K1 Filament 101273 vw Relay K2 Ano
22. Mode 10 Cooling Down Info Mode Overview of the Info Mode Viewing Cook Counter Time Logs Viewing the Fault Log Viewing the Service Numbers A Od BR Y LA NHN RH RR a 13 13 13 13 Resetting the Oven Turning Oven Options On Off Setting the Language Setting the Date Time Test Mode Testing Oven Parts Test Mode Status Indicators Test Mode Fault Log Test Mode Turning On Off Diagnostic Mode Test Mode Self Test Test Mode Manufacturing Mode Microwave Leakage Test How to Use Oven for Testing Microwave Power Test Burn In Serial Number Edit Changing Temperature Measurement Setting Self Test Erase Default Oven Settings Loading a Menu Updating the Software Edit Mode Overview of the Edit Mode Single vs Multiple Temperature Mode Changing Set Temperatures Changing Food Group Recipe Name Changing Recipe Settings Oven Systems Overview of the Convection System Blower Motor Bottom Blower Motor Top Blower Motor Controller BMSC Heater Element Jetplate Bottom Jetplate Top Stirrer Motor and Assembly Troubleshooting Overview of the Oven Door Removing Reinstalling the Oven Door Adjusting the Oven Door Interlock Switches Adjusting the Door Switches Hinges and Counter Balance Assembly Adjusting the Counter Balance Assembly Measuring RF Leakage for Microwave Safety Troubleshooting 14 14 14 14 15 15 15 15 16 16 16 16 16 17 17 17 17 17 18 19 19 20 20 21 23 23 23 23 23 23 23 2
23. air that is generated from the bottom blower motor Jetplate Top The top jetplate channels air that is generated from the top blower motor This air passes through a stirrer before entering the cook cavity through the jetplate holes CAUTION The top jetplate is ceramic Be careful when removing or reinstalling it Stirrer Motor and Assembly The stirrer is responsible for evenly distributing hot air and microwave that are launched from the top of the oven into the cook cavity The stirrer is driven by a motor that remains on during a cook cycle or when the oven is in TEST MODE The stirrer motor turns off when the cook cavity temperature recedes below 150 F 66 C The stirrer motor can be tested in TEST MODE see page 15 CAUTION Be careful to not allow debris into the waveguides when servicing the stirrer assembly SWALSAS NJAO OVEN SYSTEMS Troubleshooting Convection System The following faults may occur in relation to the convection system Fl Blower see page 39 F2 Low Temp see page 40 F6 EC Temp see page 43 F7 Thermo see page 43 F8 Heat Low see page 44 The following cooking performance issues may occur in relation to the convection system Food not browning properly see page 47 Oven Door This section contains information about the following components Oven door Interlock switches Hinges and counter balance assembly This section also contains procedur
24. injury or death A CAUTION Before removing installing any component make sure it is disconnected from the wire harness where applicable AN CAUTION Be careful to not tear the insulation when servicing components Always reset the insulation properly before reinstalling the side panel AN NOTE Hardware listed is required for installing component to oven To remove the left side cover remove the screws securing the panel to the oven frame To re install the left side cover you may need to open the top cover see page A 5 GE Item Description Item Part Number Hardware Description Hardware Part Number s 1 Blower Motor top 15 9040 Nut 1 4 20 Serr Hex Flange Plated 100906 qty 4 2 Blower Motor bottom 15 9042 Nut 1 4 20 Serr Hex Flange Plated 100906 qty 4 3 Blower Wheel top 103551 None None 4 Blower Wheel bottom 103550 None None 5 Cover Left Side 15 9301 Screw 8 Serr PHD Truss Black Oxide 101691 qty 5 6 EMI Filter 100546 Screw M5 x 8 PPHD Sems SS 101707 qty 4 7 EMI Filter Bracket 15 9257 Screw 10 32 x 3 4 lg PPH Sems Int Th 102937 qty 2 8 Heat Slinger 102708 None None 9 Helper Spring Interlock Switch 103599 None None 10 Interlock Switch Primary 102012 Screw 4 40 x 1 PPH Sems 102903 qty 2 11 Mounting Bracket Interlock Switch 115 9272 Screw 10 32 x 3 4 lg PPH Sems Int Th 102937 qty 2 12 Power Cord 15 9127 None None 13 oltage Sensor 1
25. level folder named TC_Menus NO Y YES On the USB device create a top level folder named TC_Menus Is the USB device securely attached to the oven Verify the USB device is securely attached to the connecting the reader to USB port on the oven Is the connection from USB port to control board OK Ensure the cable Ensure the cable YES the control board is securely attached and not damaged Y Replace the card reader page A 8 If the problem persists replace the control board page A 8 connecting the USB port to the control board is securely attached and not damaged YES Replace the card reader USB port page A 5 through A 6 If the problem persists replace the control board page A 8 49 DNILOOHSFIANOUL 50 TROUBLESHOOTING Troubleshooting Defective Media Message When Oven is Plugged in or Restarted Does the message prevent the oven MES from reaching the Oven Off re NO Cooling Down screen Unplug the oven and Operate the oven as then plug it back in YES you would normally Did this fix the problem NO Y Check for microwave leakage page 27 If no leakage is found replace the control board page A 8 Oven Schematic COLOR CODE LINE VOLTAGE BL BLUE
26. motor which remains on during a cook cycle or when the oven is in TEST MODE The stirrer motor can be tested in TEST MODE see page 15 CAUTION Be careful to not allow debris into the waveguides when servicing the stirrer assembly Wave Guides The wave guides channel microwave into the cook cavity If debris or contamination gets into the wave guides the life of the magnetrons may be shortened Be careful to not allow debris into the waveguides when servicing the magnetrons or stirrer assembly Troubleshooting The following faults may occur in relation to the microwave system F3 Magnetron Current Low see page 41 F5 Magnetron Over Temperature see page 42 The following issues may occur in relation to the microwave system Electrical component failure blank or scrambled display damaged control board etc Food not cooking properly 33 Control System This section contains information about the following components Control board Display Electrical compartment cooling fans Electrical compartment cooling fan thermostat Electrical compartment thermocouple EMI Filter Fuses High limit thermostat Keypad Magnetron cooling fans Magnetron thermostats Power Supply Relay K1 Filament Relay K2 Anode Relay K3 Monitor Relay K6 Voltage Relay K7 Mag fan Relay K8 Stirrer RTD Smart card reader Solid state relay K4 K5
27. of the filament transformers when they are enabled Lethal voltage will be present The installation of filament transformers is straightforward Filament transformers are wired in phase and in line Refer to the schematic on page 51 detailing the proper wiring To verify correct wiring North America measure the voltages between terminals 1 amp 2 and 1 amp 3 on FT1 and FT2 The voltages must be 208 and 240 VAC respectively SWALSAS NJAO OVEN SYSTEMS NOTE The terminals with the orange dot or the orange wire always go to Terminal 3 on US models To verify correct wiring International measure the voltage between the taps on FT1 and FT2 The voltage must be 220 VAC Latin America 200 VAC Japan or 230 VAC International High Voltage Transformers High voltage transformers are a ferro resonant design which limits fault currents and minimizes magnetron power changes due to input voltage changes The high voltage transformer supplies the high voltage for the Voltage Doubler Circuit They are controlled via the K2 relay Wiring the High Voltage Transformers DANGER Never attempt to wire or measure the secondary voltage values of the high voltage transformers with the high voltage transformers enabled Lethal voltage will be present The proper reinstallation of a high voltage transformer is critical Upon removing a high voltage transformer make sure to note where each wire was installed Refer to the oven sc
28. the change OVEN CONTROLS AND COOKING The ADJUST TIME MODE can be turned on or off from the Options screen see page 14 It is turned off by default Happens When ADJUST TIME MODE is enabled and a food item is selected from MODE 5 Goes To MODE 7 when Start Cook is selected MODE 10 if the On Off key is pressed Mode 7 Cooking Mode during which the oven cooks a food item NOTE To immediately terminate a cook cycle press the Back Stop key NOTE If the oven door is opened during a cook cycle the cycle will pause until the door is closed and Resume is selected Happens When A food item is selected from MODE 5 if MODE 6 is disabled Start Cook is selected from MODE 6 Goes To MODE 8 when the cook cycle completes Mode 8 Remove Food from Oven Mode during which the oven beeps until the oven door is opened During this mode the oven temperature remains constant WARNING Dish and inside of oven oven door are hot Use extreme caution Happens When A cook cycle completes Goes To MODE 9 if Cook More is enabled page 14 MODE 5 if Cook More is disabled MODE 10 if the On Off key is pressed Mode 9 Cook More At the completion of a cook cycle the user has the option to cook an item longer per the following Select cook more if the inside temperature of the dish is below the desired range Select brown more if the
29. the correct location TC_Menus If the menu card was created by TurboChef obtain a new menu card by contacting customer service at 800 90TURBO or 1 214 379 6000 NO YES Y Ensure the cable not damaged connecting the reader to the control board is securely attached and Name the file menudata bin and store it in a top level folder named TC_Menus Y Replace the card reader page A 8 If the problem persists replace the control board page A 8 Is the USB device securely attached to the oven NO YES Verify the USB device is securely attached to the USB port on the oven Is the connection from USB port to control board OK Y YES Ensure the cable port to the control board is securely attached and not damaged connecting the USB USB port page A 5 through A 6 If the A 8 Replace the card reader problem persists replace the control board page Troubleshooting Write Fail Message When Loading Menu u Smart Card 4 Are you trying to write to a smart card or USB device Try writing to a new smart card Was the write successful NO i Is the connection from smart card reader to control board OK NO USB Device Does the USB device contain a top
30. the time warmup initiated A WARNING Inside of oven and oven door are 11 MODE 5 when the oven temperature reaches the selected set temperature if the oven temperature needed to recover less than 126 F 70 C at the time warmup initiated MODE 10 if the On Off key is pressed Mode 4 Soak SOAK MODE provides an additional 8 minutes of warmup time for the cook cavity surfaces to warm Happens When MODE 3 completes if the oven temperature needed to recover more than 125 F 70 C at the time warmup initiated Goes To MODE 5 when counter reads 00 00 MODE 10 if the On Off key is pressed Mode 5 Ready to Cook or Idle Mode during which a food group and item can be selected for cooking hot Use extreme caution 1 Place the food into the oven 2 Select a food group by pressing its adjacent soft key or press the Up key or Down key for additional food groups if available 3 Select an item to cook by pressing its adjacent soft key Happens When MODE 3 or 4 completes Goes To MODE 6 if food item is selected and Adjust Time is enabled see page 14 MODE 7 if food item is selected and Adjust Time is disabled MODE 10 if the On Off key is pressed Mode 6 Adjust Time After a food item has been selected to cook it may be necessary to change the cook time Do so using the number keys and then press the Enter key to ONIMOOD ANY STOULNOD NJAO confirm
31. through A 6 Replace the control CZ board page A 8 YES Y Check wiring from the power supply to the Replace the display page A 8 control board Correct wiring if necessary ee NO ka NO Is the power supply receiving power YES Is the power supply output 24 VDC Is the control board receiving correct VDC Verify voltage on pin 2 of the J7 connector is 24 VDC see schematic page 51 YES Verify 5 VDC is present on pin 1 of the J7 connector If not replace the control board page A 8 Troubleshooting Food Not Cooking Properly YES y Does the problem occur for all programmed recipes For example are all recipes undercooked overcooked etc Troubleshoot the NO y Are there any fault Is the food item in the correct starting state e g frozen fresh etc codes present See page fault s using the steps gt 37 on pages 37 44 N Wa YES NO Is the menu part number and reed revision correct Verify with YES customer or contact TurboChef Customer Service NO NO roy Contact Customer Service to obtain the correct menu and load it to the oven Is the menu part number and is being properly stored prepared before cooking
32. unique temperatures 100 50 50 If 4 unique temperatures 50 50 50 50 19 AGOW 1103 20 EDIT MODE Changing Set Temperatures If a menu was loaded via smart card or USB page 17 the temperatures are already set they need not be changed The set temperature should never be changed during normal operation Changing the set temperatures is not advised to compensate for over cooking or under cooking situations Rather consult your authorized distributor or TurboChef Customer Service if recipe settings are not cooking as desired To change a set temperature 1 Place the oven in EDIT MODE see page 14 2 Select the temperature to change by pressing the adjacent soft key Figure 22 3 Using the number keys enter the new set temperature 4 Press the Enter key to confirm the change or the Back Stop key to cancel VALID RANGE BETWEEN 350 525F EDITTEMP 1 500F EDITTEMP 1 GROUPS EDITTEMP 2 500F EDITTEMP 2 GROUPS EDIT TEMP 3 450F EDIT TEMP 3 GROUPS EDIT TEMP 4 400F EDIT TEMP 4 GROUPS Figure 22 Temperature Edit Screen SELECT GROUP SCREEN 1 MUFFINS BLANK GROUP BISCUITS BLANK GROUP SETPOINT 500F BAGELS BLANK GROUP PASTRY BLANK GROUP BLANK GROUP BLANK GROUP Figure 23 Select Food Group Changing Food Group Recipe Name To change a food group or recipe name 1 Place the oven in EDIT MODE see page 14 2 Select a block of food groups by pressing the corresponding right si
33. 0 Removing Opening Multiple Covers Required Figure A 11 Counter Balance Assembly Hinge and Switch Detail A 13 SLNINO4IWOD NAO DNIDV 1434 XIGNAddV For service or information WITHIN NORTH AMERICA CALL Customer Service at 800 90TURBO or OUTSIDE NORTH AMERICA CALL 1 214 379 6000 or Your Authorized Distributor Accelerating the World of Cooking Part Number i5 9231 Revision B March 2008 Country Code NA EU Corporate Headquarters Six Concourse Pkwy Suite 1900 Atlanta Georgia 30328 USA 1 678 987 1700 PHONE 1 678 987 1750 FAX Global Operations 4240 International Pkwy Suite 105 Carrollton Texas 75007 USA 1 214 379 6000 PHONE 1 214 379 6073 FAX turbochef com
34. 00783 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 1 NOTE For more interlock switch detail see Figure A 11 page A 13 SLNAINOdWOD NJAO ONIDVId38 XIGNAddV A 10 APPENDIX REPLACING OVEN COMPONENTS Ser Re See ae QUULULU MELO Fremen GW COU Figure A 7 Removing Left Side Cover Required Figure A 8 Blower Motor Assembly Replacing Items Removing Right Side Cover Required Figure A 9 A DANGER Before replacing any oven component ensure the oven is removed from any power source Replacing a component while the oven is plugged in can result in serious injury or death A CAUTION Before removing installing any component make sure it is disconnected from the wire harness where applicable DA NOTE Hardware listed is required for installing component to oven To remove the right side cover 1 Remove the screws securing the panel to the oven frame 2 Remove the right side cover Figure A 9 Removing Right Side Cover Required y y 4 y y y Y E gene Item Description Item Part Number Hardware Description Hardware Part Number s Reference 1 Catalytic Converter 15 9066 None None 2 Cover Right Side 15 9302 Screw 8 Serr PPHD Truss Black Oxide 101691 qty 5 3 Heater Assembly 15 9284 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 10 4 Helper Spring Interlock Switch 103599 None None 5 Interloc
35. 3 24 24 24 24 26 26 26 26 27 28 Overview of the Microwave System Capacitors Testing a Capacitor Filament Transformers Wiring the Filament Transformers High Voltage Transformers Wiring the High Voltage Transformers Testing a Filament or High Voltage Transformer High Voltage Diodes Testing a High Voltage Diode Magnetrons Testing a Magnetron for an Open Shorted Filament Stirrer Motor and Assembly Wave Guides Troubleshooting Overview of the Control System Control Board Display Electrical Compartment Cooling Fans Electrical Compartment Cooling Fan Thermostat Electrical Compartment Thermocouple EMI Filter Fuses High Limit Thermostat Keypad Magnetron Cooling Fans Magnetron Thermostats Power Supply Relay K1 Filament Relay K2 Anode Relay K3 Monitor Relay K6 Voltage Relay K7 Magnetron Cooling Fan Relay K8 Stirrer Motor RTD Smart Card Reader Solid State Relay K4 K5 Heater Speaker USB Port Voltage Sensor Wire Harness Troubleshooting Overview of the Filtering System Catalytic Converter Drain Pan Air Filter Vent Catalyst Troubleshooting 29 29 29 29 29 30 30 30 30 31 32 32 32 32 32 33 33 33 33 33 33 33 22 34 34 34 34 34 34 34 34 34 35 35 35 35 gt bs 35 35 35 35 36 36 36 36 36 36 Troubleshooting Overview of Troubleshooting Fault Code Descriptions Fault Code Troubleshooting F1 Blower Running Status Bad Fault Code
36. 3 200 VAC 50 60 Hz 1 amp 2 3 4 very low resistance if read ing is open transformer has failed High Voltage and Filament Transformer Resistance Table When the high voltage winding starts to go toward 2 Fully discharge the capacitors negative the high voltage diode becomes non 3 Connect the voltage meter in series with diode conducting with the charged high voltage capacitor in series with the high voltage winding When the transformer gets to its negative peak of 2400 VPK the voltage applied to the filament is negative 4500 volts The high voltage diodes are rated at 16 kVDC Testing a High Voltage Diode DANGER Never attempt to measure high voltage directly Death or serious injury could result 1 Disconnect the oven from the power source N Using a multimeter set to DC voltage connect one meter lead to one side of a 9 volt battery and the other lead to one side of the diode Connect the other side of the 9 volt battery to the other side of the diode DC voltage should only be present on the meter in one direction Switch the meter leads on the diode which will cause the opposite reading to be visible Depending on the voltage of the battery voltage between 5 7 VDC should be present in only one direction and 0 0 1 VDC in the other direction 31 SWALSAS NINO OVEN SYSTEMS Magnetrons Figure 30 Magnetrons supply the RE energy at 2 45 GHz and begin to oscillate when th
37. 3181 The use of any other cleaning products can damage Nylon scrub pad cleaning towel disposable gloves critical oven components resulting in a protective eyewear dust mask optional pair of non warranty service call tongs wrapped with towel optional see step 11 Step 1 Prepare the Oven A WARNING Oven operates at approximately 450 F 232 C and may cause injury if not allowed to cool properly Turn off the oven by pressing the On Off key Slightly open the oven door Cooling takes approximately 40 minutes DO NOT attempt to clean the oven until the oven displays Oven Off Step 2 Remove and Clean the Wire Rack A WARNING Be sure the oven interior is cool before you remove the wire rack Wash rinse and sanitize the wire rack Step 3 Remove and Clean the Lower Jetplate Unscrew the two thumb screws on the lower jetplate Lift the lower jetplate by gripping the thumb screws Remove the lower jetplate Wash rinse and sanitize the lower jetplate Step 4 Remove and Clean the Lower Air Diverter Remove the lower air diverter Wash rinse and sanitize the lower air diverter A WARNING DO NOT discard the lower air diverter The oven will not work without the lower air diverter installed Step 5 Wipe the Oven Interior Wipe any large particles from the oven interior with a damp towel Step 6 Clean the Oven Interior Spray oven cleaner onto the top bottom and sides of the ove
38. 8 Heat Low This fault displays during WARMING UP or TEST MODE if the cook cavity temperature fails to rise at least 14 F 7 C within a given 30 seconds F1 Blower Running Status Bad Y Y v v Page 39 F2 Cook Temperature Low v Page 40 F3 Magnetron Current Low v v Page 41 F4 Door Monitor Defective v v Page 42 F5 Magnetron Over Temperature v v Page 42 F6 EC Temperature High v v v v Page 43 F7 RTD Open v v Y Y Page 43 F8 Heat Low Y v Page 44 Figure 32 Fault Code Table Fault codes are listed in order of hierarchy For example if during cooking the oven experiences an F1 and F2 fault the oven will report only the F1 fault because the software will halt all actions upon discovering the F1 fault Fault codes F1 F5 and F7 will terminate a cook cycle upon discovery Fault Code Troubleshooting From TEST MODE you can run oven diagnostics and check fault counts To access TEST MODE or turn on Diagnostic mode see page 15 Troubleshooting F1 BLOWER Blower Running Status Bad Is the wiring harness properly connected Check the motor controller top and bottom blower motors and I O control board See page 51 for schematic Are Status Indicators B and T backlit in TEST MODE see page 15 r YES m NO YES Is each blower motor spinning freely Remove obstruction or if neces s
39. Blower motor controller Heater element Jetplate bottom Jetplate top Stirrer motor and assembly For information on accessing and removing parts see the Appendix Blower Motor Bottom The convection motor is a brushless AC switch reluctance type Its top speed is 7100 RPM at 1 HP The motor is controlled by a proprietary controller The bottom blower spins clockwise The bottom blower motor can be tested in TEST MODE see page 15 Blower Motor Top The convection motor is a brushless AC switch reluctance type Its top speed is 7100 RPM at 1 HP The motor is controlled by a proprietary controller The top blower spins counterclockwise The top blower motor can be tested in TEST MODE see page 15 Blower Motor Controller BMSC The motor controller is proprietary and will only operate the convection motors described above The motor controller is controlled on command from the I O control board and a 0 10VDC speed command from the I O control board The blower motor controller can be tested in TEST MODE by testing the blower motors see page 15 For additional troubleshooting see page 39 Heater Element The main convection heater is a finned style heater rated at 3000 watts at 208 VAC with a resistance of 14 4 Ohms The convection heater is controlled by the K4 K5 solid state relay The heater element can be tested in TEST MODE see page 15 Jetplate Bottom The bottom jetplate channels
40. C TRANSFORMERS TAPS 1 2 ARE CONNECTED JUMPER FO Paz EERATION ONLY BETWEEN PIN 1 amp 3 CA un yg ry C 12 2 2K 1 2W Lu MAGNETRON OVERTEMP MAG 1 MAG 2 212 F 100 C 212 F 100 C OT3 c OT4 de NCPC 32 T NG e 232 N 11 MANUAL RESET T1 HX 2 3000 W 14 4 OHMS 2 F1 12 AMPSCLASSCC F2 12 AMPSCLASSCC F3 12 AMPSCLASSCC F4 12 AMPSCLASSCC SUBSTITUTE IEC 3 PIN PLUG Jl lio APPLICATION QC9 RTD K3 RELAY ASSY HX 1 3000W 14 4 OHMS APPROVED DCASTILLO DRAWN DAVID CASTILLO 08 14 2006 CHECKED SCHEMATIC i5 MULTIPHASE 208 240 VAC 60 HZ PA SHEET 1 0F1 Figure 34 i5 Oven Schematic DILWWAHDS NJAO This page intentionally left blank Appendix Replacing Oven Components Comprehensive Table of Oven Components A NOTE For hardware see the illustrations contained in this appendix NM DANGER Before replacing any oven component ensure the oven is removed from any power source Replacing a component while the oven is plugged in can result in serious injury or death
41. If one opens the control will switch off both microwave systems until the open thermostat closes The thermostats are self resetting Power Supply The power supply outputs 24 VDC at 40 watts to the control board and relays Relay K1 Filament The K1 relay is a 240 VAC 30 amp double pole double throw 24 VDC relay coil It switches power to the magnetron filament transformers Relay K2 Anode The K2 relay is a 240 VAC 30 amp double pole double throw 24 VDC relay coil It switches power to the magnetron high voltage transformers Relay K3 Monitor The K3 relay is a 240 VAC 30 amp double pole double throw 24 VDC relay coil It shorts L1 and L2 if the monitor switch opens before the primary or secondary switches Relay K6 Voltage The K6 relay is a 240 VAC 30 amp three pole double throw 24 VDC relay coil Applicable in North America only it switches between 208 and 240 VAC on the high voltage transformer and filament transformer taps depending on incoming voltage 35 Relay K7 Magnetron Cooling Fan The K7 relay is a 240 VAC 30 amp double pole double throw 24 VDC relay coil It switches power to the magnetron cooling fans when the magnetron filaments are actuated Power is switched off after 4 minutes 15 seconds NOTE The 4 15 timer starts over each time the magnetron filaments are actuated Relay K8 Stirrer Motor The K8 relay is a 240 VAC 30 amp double pole double throw 24
42. See page 51 for schematic YES NO I Is the RTD functioning properly Correct wiring Replace the I O control board page A 8 Ensure wiring is correct If necessary replace RTD page A 11 14 4 Ohms NO YES i Replace the defective heater page A 11 Y Is the solid state relay defective YES y Replace the solid state relay page A 5 Troubleshooting F3 MAG CURR Magnetron Current Low Is control board detecting 10A or Intl more current Test Is the oven U S or International Is the K6 mechanical US relay in good working order YES for 24 VDC on pin i 2 of J7 connector Replace the NO Y page 51 control board Check the condition of the Replace K6 relay See page A 8 F3 and F4 fuses pages 42 see pages A 5 YES NO 1 A 5 through A 6 Are they through A 6 YES 12 amps l YES No Replace the F3 Is amperage present at the NO and or P4 fuse see current transformer even pages A 5 through if the control board is not Are the F3 and F4 fuses AE verify the detecting it functioning properly NUR operation of the i interlock switches YES page 26 Y oy Test the high voltage Run test cook cycles to see if fault YES repeats page 10
43. Side Views L First remove TT switches then tap here Figure 26C Door Misaligned Variation 2 Side Views 25 SWALSAS NINO OVEN SYSTEMS Interlock Switches The primary secondary and monitor interlock switches engage and disengage in sequence to ensure a proper seal When the door is opened the switch sequence is P S M Subsequently the sequence is M S P when the door is closed Adjusting the Door Switches NM WARNING Procedure requires work while the oven is hot As a result exercise extreme caution when adjusting the door switches 1 Ensure the oven door is closed 2 Verify the oven door is not misaligned If it is align it see procedure on page 24 illustrations on page 25 3 If the door is properly aligned loosen the hex screws on the switch bracket and slide the bracket accordingly until each switch is just engaged If the bracket is properly positioned but the switches are not slide the switches until they just engage 4 Allow the oven to warm up to the set temperature If more than one set temperature is present select the highest 5 Once the oven warms to the set temperature go to TEST MODE page 15 6 Check the status indicators P S and M to verify the switches open and close in the correct sequence P S M when the door is open and M S P when the door is closed 7 If necessary repeat steps 3 6 8 Perform a MW Leak Test adjacent Hinges and Coun
44. The voltage sensor does not compensate for lack of or over voltage installations Multi Phase i5 EW model i5 9500 4 EW Voltage 400 VAC Frequency 50 Hz Current 19 amps Max Input 10000 watts Plug IEC 309 5 pin i5 AU model i5 9500 5 AU Voltage 400 VAC Frequency 50 Hz Current 19 amps Max Input 10000 watts Plug Clipsal 5 pin iS KW model i5 9500 12 KW Voltage 400 VAC Frequency 60 Hz Current 19 amps Max Input 10000 watts Plug IEC 309 5 pin iS ED model i5 9500 3 ED Voltage 230 VAC Frequency 50 Hz Current 28 amps Max Input 10000 watts Plug IEC 309 4 pin iS SD model i5 9500 13 SD Voltage 230 VAC Frequency 60 Hz Current 28 amps Max Input 10000 watts Plug IEC 309 4 pin i5 JD model i5 9500 9 JD 50 Hz i5 9500 11 JD 60 Hz Voltage 200 VAC Frequency 50 or 60 Hz Current 25 amps Max Input 10000 watts Plug PSE marked 4 blade Figure 2 Hand Grip Locations A Install or locate this appliance only in accordance with the instructions below Unpacking Instructions 1 2 Remove oven from packaging Before discarding packaging check thoroughly for accessories consumables and literature Discard packaging Check cook cavity thoroughly for accessories consumables and literature Discard any packaging
45. Troubleshooting F2 Cook Temperature Low Fault Code Troubleshooting F3 Magnetron Current Low Fault Code Troubleshooting F4 Door Monitor Defective Fault Code Troubleshooting FS Magnetron Over Temperature Fault Code Troubleshooting F6 Electrical Compartment Temperature High Fault Code Troubleshooting F7 Open RTD Fault Code Troubleshooting F8 Heat Rise Low Non Fault Code Troubleshooting No Keypad Input Non Fault Code Troubleshooting Door Open Message when Door is Closed Non Fault Code Troubleshooting No Display Screen is Blank Non Fault Code Troubleshooting Food Not Cooking Properly Non Fault Code Troubleshooting Read Fail Message when Loading a Menu Non Fault Code Troubleshooting Write Fail Message when Loading a Menu Non Fault Code Troubleshooting Defective Media Message When Oven is Plugged in or Restarted Oven Schematic Appendix Replacing Oven Components Comprehensive Table of Oven Components Replacing Items No Cover Removal Required Replacing Items Opening Top Cover Required Replacing Items Removing Top Cover Required Replacing Items Removing Left Side Cover Required Replacing Items Removing Right Side Cover Required Replacing Items Removing Opening Multiple Covers Required 37 37 39 40 41 42 42 43 43 44 45 45 46 47 48 49 50 51 A 1 A 3 A 5 A 7 A 9 A 11 A 12 Safety Instructions Strictly adhere to the following safety precaut
46. VDC relay coil It switches power to the stirrer motor RTD The RTD measures the temperature of the heater element If the display reads 999 F C the RTD is open resulting in an F7 fault See page 43 for troubleshooting Smart Card Reader The smart card reader allows the oven operator to load a menu software updates from a smart card A menu that already exists in the oven can also be saved to a smart card For instructions see page 17 Solid State Relay K4 K5 Heater The solid state relay is a 240 VAC dual 40 amp relay K4 right switches power to heater 1 K5 left switches power to heater 2 Speaker The speaker provides audible feedback to the oven operator whenever a key is pressed or a task such as a cook cycle is completed etc USB Port The USB port allows the oven operator to load a menu software updates from a USB drive A menu that already exists in the oven can also be saved to a USB drive For instructions see page 17 Voltage Sensor For North America oven models the oven will detect 208 or 240 incoming voltage The initial voltage selection is typically completed before the oven is used by the customer However if incoming voltage for the store is different than the preset voltage the operator will be required to select either 208 or 240 after pressing the On Off key to turn on the oven The correct voltage will be enlarged on the screen identifying which option to select Wire Ha
47. am Weldment LHS 15 9313 Washer Nylon Hingepin C0504 qty 1 4 Hinge Cam Weldment RHS 15 9314 Washer Nylon Hingepin C0504 qty 1 5 Hinge Guide Switch Slide Lower 15 9316 Screw 10 32 x 3 8 lg PFLH 100 Deg SS 101401 qty 2 6 Hinge Guide Switch Slide Upper 15 9315 Nut Keps Hex 8 32 Ext Tooth Cres 102962 qty 4 7 Hinge Gusset LHS 15 9178 Nut 1 4 20 Serr Hex Flange Plated Steel 100906 qty 2 8 Hinge Gusset RHS 15 9179 Nut 1 4 20 Serr Hex Flange Plated Steel 100906 qty 2 9 Hinge Module Base 15 9193 None None 10 Hinge Torsion Bar 15 9144 Spacer Adjustment Call TurboChef 11 Hinge Weldmt CtrbInce Brkt LHS 15 9326 Screw 10 32 x 3 8 lg PFLH 100 Deg SS 101401 qty 3 12 Hinge Weldmt Ctrblnce Brkt RHS 15 9327 Screw 10 32 x 3 8 lg PFLH 100 Deg SS 101401 qty 3 13 Magnetron Left NGC 3015 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 4 14 Magnetron Right NGC 3015 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 4 15 Thermostat Magnetron Left 102070 Screw Sh Mtl Drill Point 6 32 x 3 8 PPHD Zinc 101684 qty 2 16 Thermostat Magnetron Right 102070 Screw Sh Mtl Drill Point 6 32 x 3 8 PPHD Zinc 101684 qty 2 17 Waveguide Left 15 9330 Nut Keps Hex 1410 32 Ext Tooth Cres 102963 qty 9 18 Waveguide Right 15 9330 Nut Keps Hex 10 32 Ext Tooth Cres 102963 qty 9 19 Waveguide Gasket Left 15 9331 None None 20 Waveguide Gasket Right 15 9331 None None Figure A 1
48. ary replace blower motor s pages A 9 through A 10 NO Y Do resistance measurements between windings and chassis agree with values on motor windings resistance table Figure 33 below r YES NO YES Is output from I O board to harness 1 10 volts Verify at test points YES NO Correct the wiring or replace I O control board page A 8 motor controller page A 7 NO Replace the I O board page A 8 Replace motor controller page A 7 Replace the blower motor s Be sure to check both the top and bottom blower motors pages A 9 EE through A 10 To From Description Expected Resistance Black Red Winding A B 5 9 7 3 Ohms Black White Winding A C 5 9 7 3 Ohms Red White Winding B C 5 9 7 3 Ohms Black Red or White Green Windings to Chassis Open Figure 33 Motor Windings Resistance Table 39 ONILOOHSI19NOY4L 40 TROUBLESHOOTING Troubleshooting F2 LOW TMP Cook Temperature Low Reset and determine why it tripped excess grease buildup etc Figure 31 page 34 YES Is the high limit thermostat tripped Is either of the heater ele NO gt ments defective heaters should have a resistance of Is wiring from the solid state relay to the I O control board OK Ht NO
49. ations Capacitor rating is 0 85uF 2500 VDC for 60 Hz Japan installations Testing a Capacitor DANGER Never attempt any measurement of the capacitors while they are enabled Lethal voltage will be present Measure only in compliance with these procedures Disconnect the oven from the power source Fully discharge the capacitor Isolate the capacitor from the circuit mB OG NN ra Check for an open or shorted capacitor by placing ohmmeter leads between the capacitor terminals Inconsistent readings capacitor OK Constant infinite resistance capacitor open Constant very low resistance capacitor shorted 5 If the capacitor is not open or shorted set the meter to measure capacitance and again place the leads between the capacitor terminals The meter reading should equal the label value plus or minus 10 If not replace the capacitor Filament Transformers For better operation and reliability the oven uses separate transformers in order to preheat the magnetron filament The control energizes the filament transformers for approximately five seconds prior to energizing the Microwave Circuit via the high voltage transformers When in operation the filament transformers supply approximately 3 15 VAC at 10 amps to each magnetron filament The filament transformers are controlled via the K1 relay Wiring the Filament Transformers DANGER Never attempt to measure the secondary voltage values
50. ble on some oven models From screen 2 of the INFO MODE press the L3 soft key to set a different language Each time L3 is pressed a different language is selected in the following order English default Spanish French German Portuguese Italian Russian Greek Polish OVEN OPTIONS ADJ TIME OFF DHCP OFF COOKMORE ON EDIT MODE ON LOAD MENU ON DEMO MODE OFF Figure 12 Options Screen Setting the Date Time Figure 13 Having an accurate date and time is important for logging oven counts diagnostics and fault conditions should any occur The oven time and date are set at the time of manufacture however the operator may at some point be required to make an adjustment From screen 2 of the INFO MODE press the L4 soft key to access the Set Date Time screen To set the date and time 1 Use the L3 and R3 soft keys middle left and middle right to navigate between fields 2 Use the numeric keypad to enter the month day and year followed by the hour and minute NOTE The clock is a 24 hour clock e g 20 30 8 30 PM 3 Select Save to save your changes or Cancel to cancel and exit the screen NOTE The oven will not retain the time if it is left unplugged for two or more weeks SET DATE TIME MM DD YY 09 29 08 CANCEL Figure 13 Set Date Time Test Mode Testing Oven Parts From screen 2 of the Info mode press the L1 soft key to access TEST MODE When pr
51. d was successful If a second card was provided insert it When the oven restarts and the display turns on the update is complete Remove the smart card NOTE If the update is unsuccessful the display will remain off and the oven will beep one long low tone If this occurs repeat the above procedure If the update fails multiple times a smart card may be damaged Contact TurboChef to obtain a new smart card Smart Card USB Port Smart Card Reader Slot Figure 21 Inserting Smart Card USB Device Edit Mode Overview of the Edit Mode The EDIT MODE serves three main purposes 1 To edit set temperatures 2 To edit names of food groups and recipes 3 To edit recipe settings To access the EDIT MODE 1 Enable it from the Options screen page 14 2 Press the On Off key to return the oven to the Cooling Down or Off screen 3 Press the On Off key again to enter EDIT MODE Single vs Multiple Temperature Mode The i5 Oven is capable of utilizing four unique set temperatures By default the oven operates in Single Temperature mode in which all four temperatures are the same By contrast if more than one temperature is specified in the EDIT MODE the oven will operate in Multiple Temperature mode The i5 Oven is capable of storing 200 recipes If more than one temperature is desired at least 50 recipe spots must be allocated to each unique temperature
52. de 101273 v Relay K3 Monitor 101273 v Relay K6 Voltage 101272 vw Relay K7 Mag Fan 101273 Vv Relay K8 Stirrer 101273 Vv Relay Bracket 15 9261 v Relay Solid State K4 K5 Heaters 101286 Vv RTD Cook Cavity HHC 6517 Y Shunt Plate Assembly 15 9307 D Door Smart Card USB Port CON 7005 Vv Control Board Speaker 104155 vw Stirrer 15 9154 vw Top Jetplate Stirrer Hub 104132 vw Stirrer Motor Stirrer Motor 15 9361 wi Stirrer Mtr Bracket Stirrer Motor Bracket 15 9075 v Stirrer Shaft 15 9151 v DN Thermocouple EC 700 1199 v See page A 12 through A 13 for removing door hinge components magnetrons magnetron thermostats or waveguides Thermostat Cooling Fans 102086 v Thermostat High Limit 102075 v Filter Filter Bracket Thermostat Magnetron Left 102070 Vv v Magnetron Left Thermostat Magnetron Right 102070 vw v Magnetron Right Transformer Filament NGC 3061 1 v Transformer High Voltage NGC 3062 1 v Vent Catalyst Foil Pack RWD 9191 v Vent Tube Cover Vent Tube Cover 15 9209 v Heat Chnl Widmt Voltage Sensor 100783 Y Mag FT Diode Waveguide Left 15 9330 v v Bracket Capacitor WG Gasket Mag FT Diode Waveguide Right 15 9330 v v Bracket Capacitor WG Gasket Mag FT Diode Waveguide Gasket Left 15 9331 v Y Bracket Capacitor WG Gasket Mag FT Diode Waveguide Gasket Right 15 9331 v v Bracket Capacitor WG Gasket Weldment H
53. de soft key Figure 22 NOTE Earlier i5 software versions store only two temperatures each containing 2 food group blocks SS 3 Select the group that contains the recipe s you want to edit Figure 23 4 Select a recipe to edit Figure 24 5 From the Recipe Edit screen Figure 25 edit the food group name Use the numeric keypad to change a character Press the R1 soft key to advance to the next character Press the L1 soft key to return to the previous character Press the R3 soft key to save changes 6 Edit the recipe name Press the Down key to move to the Recipe Name field Use the instructions provided in step 5 to edit the recipe name SINGLE Miu RECIPE 6 X2 RECIPE 7 X3 RECIPE 8 X4 RECIPE 9 X6 RECIPE 10 Figure 24 Select Recipe to Edit MUFFINS RECIPE 6 TIM EVENT TIM TOP BOT WAV 025 020 020 050 025 040 060 025 025 060 040 075 025 090 100 010 000 010 010 000 000 010 010 000 000 010 010 000 000 010 010 000 TOTAL 100 TOTAL TIME 01 40 PSM TCC 482F Figure 25 Recipe Edit Screen 21 Changing Recipe Settings Recipe settings consist of the following 6 Use the Down key to move the cursor to the Up to eight events or stages of the cook cycle Total Time field Cook time NOTE To help make navigation easier the R To change recipe settings Time soft key jumps the cursor to the total time 1 Place the ove
54. e chemicals or vapors in this appliance it is not designed for industrial or laboratory use x DO NOT operate this appliance if it has a damaged cord or plug is not working properly or has been damaged or dropped See Power Cord Replacement found on page ii DO NOT cover or block any openings on this appliance DO NOT store this appliance outdoors DO NOT use this product near water e g near a kitchen sink in a wet basement near a swimming pool DO NOT immerse cord or plug in water DO NOT let cord hang over the edge of table or counter x XA x x x Se DO NOT use a water jet for cleaning See the Maintenance section pages 7 8 for proper cleaning procedures Reducing Fire Risk v Remove wire twist ties from paper or plastic bags used to facilitate cooking in the oven v If materials inside the oven ignite keep the oven door closed turn the oven off and disconnect the power cord or shut off power at the fuse or circuit breaker panel v If smoke is observed switch off or unplug the oven Keep the door closed to stifle any flames x DO NOT use the cook cavity for storage purposes x DO NOT overcook food Carefully attend to the oven if paper plastic or other combustible materials are placed inside the oven to facilitate cooking x DO NOT leave paper products cooking utensils or food in the cavity when not in use SAVE THESE INSTRUCTIONS SNOLLIN4LSNI AL34VS SAFETY INSTRUCTIONS Grounding Instructions Thi
55. eadjust the monitor safety switch See page 26 for instructions Disconnect oven from power supply _ land then reconnect The fault should clear YES Y Are the switches NO closing in the Disconnect oven from power supply and then YES reconnect The fault correct sequence M S P should clear Troubleshooting F5 MAG TEMP Magnetron Over Temperature Verify wiring If neces i Is the airpath into the electri sary replace the cooling Open the top cover place the oven in cal compartment blocked or fans see pages A 7 NO TEST MODE and test the magnetrons eg clogged with debris Check through A 8 see page 15 Are the magnetron the cooling fan finger guards cooling fans operating and filter on the back panel Verify wiring to magnetrons and verify TEN NO YES von Do the magnetrons pass testing in the magnetron thermostats are TEST MODE See page 15 not open Are wiring and ee debris thermostats ok YES or reposition the Fault message oven away from NO should disappear a obstruction Y YES Correct wiring Replace the magnetron s page A 12 stats pages A 12 YES gt through A 13 and test again in TEST NO through A 13 MODE Do the magnetrons pass testing replace the thermo Replace the control board
56. eat Channel Vent Tube NGC 1397 v See page A 12 through A 13 for removing door hinge components magnetrons magnetron thermostats or waveguides Replacing Items No Cover Removal Required Figures A 1 A 2 DANGER Before replacing any oven component ensure the oven is removed from any power source Replacing a component while the oven is plugged in can result in serious injury or death wire harness where applicable NOTE Hardware listed is required for installing component to oven AN CAUTION Before removing installing any component make sure it is disconnected from the 1 Door Assembly 15 9308 Screw 8 32 x 3 8 PFH 100 Deg SS 102809 qty 6 2 Door Gasket 15 9309 None None 3 Door Handle 15 9253 Screw 1 4 20 x 25 lg Serrated Hex 102947 qty 4 4 Door Skin 15 9109 Screw 6 32 x 38 PFH 100 Deg SS 101430 qty 9 5 Drain Pan 15 9252 None None 6 Filter Air 15 9039 None None Zu 5500 SE Ee 8 Hand Grip 15 9256 Screw 8 X 1 2 Serrated PHTRH Black Oxide 101691 qty 2 9 Jetplate Bottom 15 9159 N A Included with part SLNAINOdWOD N3AO DNDV 1434 XIGNAddV APPENDIX REPLACING OVEN COMPONENTS ae 4 Item Description Item Part Number Hardware Description Hardware Part Number s 10 Jetplate Top 15 9203 None None 11 Lower Front Panel i5 9246 None None 12 Rack 15 9168 None None 13 Rack Suppor
57. er load each time a new area is measured or if measurement of an area takes longer than 60 seconds 10 After each test is complete open the oven door and dispose of the hot water Troubleshooting The following faults may occur in relation to the oven door F4 Monitor see page 42 The following issues may occur in relation to the oven door Cook Door Open message when door is closed see page 45 29 Microwave System The i5 oven employs two independent microwave systems left and right In the case of an over current situation relative to the left system the F3 fuse will blow In the case of an over current situation relative to the right system the F4 fuse will blow This section contains information about the following components Capacitors Filament Transformers High Voltage Diodes High Voltage Transformers Magnetrons Stirrer Motor and Assembly Wave Guides This section also contains procedures for Testing a capacitor Wiring the filament transformers Testing a filament transformer Testing a high voltage diode Wiring the high voltage transformers Testing a high voltage transformer Testing a magnetron for an open shorted filament For information on accessing and removing parts see the Appendix Capacitors Capacitor rating is 0 91uF 2500 VDC for all 60 Hz installations except Japan Capacitor rating is 1 15uF 2500 VDC for all 50 Hz install
58. erefore only TurboChef Oven Cleaner should be used CAUTION Clean the catalytic converter with TurboChef Oven Cleaner and rinse thoroughly with distilled water Let the catalytic converter air dry before reinstalling If TurboChef Oven Cleaner is not available do not use a substitute Use distilled water only Drain Pan The drain pan collects debris as it is flushed through the bottom of the cook cavity Air Filter The filter is located on the back of the oven It helps prevent debris from getting into the electrical compartment Vent Catalyst In addition to the main catalytic converter the i5 oven contains an additional catalyst in the vent tube path This catalyst further assists in the breakdown of grease and particulate matter before the excess air enters the atmosphere Troubleshooting The following issues may occur in relation to the filtering system Fire in the cook cavity if catalytic converter is clogged and oven is not regularly cleaned Electrical component failure if filter is not present or is clogged Undesirable flavor transfer Undesirable odor emissions Troubleshooting 37 Overview of Troubleshooting This section contains information on the following Fault code descriptions Fault code troubleshooting Non fault code troubleshooting For information on accessing TEST MODE see page 15 For information and illustrations on replacing components see the appendix
59. es for Removing reinstalling the oven door Adjusting the oven door Adjusting the oven door switches Measuring RF leakage for microwave safety For information on accessing and removing parts see the Appendix The proper fit and adjustment of the oven door is essential for safe and reliable oven operation The oven door assembly consists of a shunt plate skin and handle Each of these items can be purchased independently Removing Reinstalling the Oven Door To remove or reinstall the oven door follow the steps below For illustrations see page A 4 1 Ensure the oven has cooled to 150 F 66 C 2 Open the oven door to its full open position 3 Locate and remove 8 32 screws 3 per side 4 Carefully remove the oven door by pulling the door away from the oven It will slide off the hinges and the hinge blocks will stay in place See Figure A 1 page A 4 5 To reinstall or fit a new door carefully slide it back over the hinge blocks and replace the 6 8 32 screws 3 each side 6 Verify that the door is parallel to the oven frame If it is not parallel adjust the door per the instructions below 7 From TEST MODE check the status indicators P ES and M to verify the switches engage door closed and disengage door open properly If they do not adjust the switches per the instructions on page 26 8 Complete a MW leakage test page 27 Adjusting the Oven Door N WARNING Procedu
60. ey are supplied with approximately 4 1 kVDC at approximately 350 mA During operation each magnetron will output a nominal 1 kW of power If replacement is required conduct a microwave leakage test page 27 after installation of new magnetron FAC Ur FILAMENT AND HIGH VOLTAGE TERMINALS acu Figure 30 Magnetron Testing a Magnetron for an Open Shorted Filament DANGER The only safe way to test a magnetron is by a resistance test of its filament Never attempt to measure the magnetron using any other method while the microwave system is on Death or serious injury could occur Disconnect the AC power source and discharge the high voltage capacitors 2 Isolate the magnetron from the circuit by removing the wires from the F and FA terminals Figure 30 3 An ohmmeter connected between the filament terminals F FA should indicate a reading of less than 1 ohm Figure 30 4 A continuity check between either filament terminal and the magnetron chassis should indicate an infinite resistance open AN CAUTION Be careful to not allow debris into the wave guides when servicing the magnetrons Stirrer Motor and Assembly The stirrer is responsible for evenly distributing hot air and microwaves that are launched from the top of the oven into the cook cavity The stirrer is driven by a 3 6 RPM
61. he serial number Use the number letter keys to change a character After one second the cursor will advance to the next character Press the R3 soft key to advance to the next character Press the L3 soft key to return to the previous character Press the R5 soft key to save the changes or the L5 soft key to cancel Changing Temperature Measurement Setting From the manufacturing mode screen press the L5 soft key to change the temperature measurement from Fahrenheit to Celsius or vice versa Self Test Press the R1 soft key to access Self Test Self Test is also accessible from the TEST MODE screen see page 16 for more details about Self Test Erase Default Oven Settings N CAUTION Settings cannot be retrieved once an erase option is confirmed Press the R5 soft key to access the Erase screen From the Erase screen Press the L2 soft key to erase counters and fault logs Press the R2 soft key to erase counters fault logs menu settings temperature settings serial number date and time Doing so will also default all oven options page 14 for more detail to OFE with the exception of load menu LOAD FROM CARD SAVE TO CARD LOAD FROM USB SAVE TO USB Figure 19 Load Menu Screen 17 Loading a Menu From screen 2 of the INFO MODE press the R1 soft key to access the Load Menu screen Figure 19 NOTE This feature can be turned on or off via the Options
62. hematic page 51 detailing the proper wiring As shown in the schematic transformers are installed mirror opposite and wired 180 out of phase It is essential for longevity that the high voltage transformers remain 180 out of phase This can be checked by placing a volt meter across terminals T1 1 and T2 1 primary voltage With the microwave system energized the volt meter will read the incoming voltage different readings for different electrical installations If the meter reads 0 VAC the high voltage transformers are most likely wired in phase As a last check energize the microwave system and verify the voltages between the taps on each high voltage transformer The wiring issue must be corrected prior to return ing the oven to service as the voltages must be NORTH AMERICA 208 VAC between 1 amp 2 and 240 between 1 amp 3 LATIN AMERICA 220 VAC JAPAN 200 VAC INTERNATIONAL 230 VAC NOTE The terminals with the orange dot orange wire always go to terminal 3 on USA models Testing a Filament or HV Transformer DANGER Never attempt to measure the secondary voltage values of the transformers when they are enabled Lethal voltage will be present 1 Disconnect the AC power source and discharge the high voltage capacitors 2 Disconnect all the wires in question going to the transformer 3 Use an ohmmeter to check the impedance of the primary and secondary winding Refer to the adjacent resista
63. inutes if the oven starts cold Once the oven has warmed up place the oven in TEST MODE see page 15 From TEST MODE select MFG Mode From the Manufacturing Mode screen select MW Leak Test and follow the instructions on the screen also detailed in following steps Place a water load into the cook cavity Water load must conform to the following specifications Volume 275 ml 15 ml Temperature 68 F 9 F 20 C 5 C Vessel Low form 600 ml beaker with an inside diameter of approximately 3 35 85 mm and made of Pyrex or equivalent 27 SWALSAS NJAO 28 OVEN SYSTEMS Figure 28 Survey Meter Placement Close the oven door and press the Enter key The microwave system will turn on Position the microwave survey meter as shown in Figure 28 above Measure microwave emission around the door moving the meter sensor at 0 5 inches second As microwave leakage is observed moving the sensor at 0 5 inches second note any meter spike areas that come close to 5mW cm for later re measurement Replace the water load every 60 seconds until the test is completed and also after scanning the door Close the oven door and return the meter probe to any meter spike areas and allow the probe to remain in the spike area for 17 seconds Note the highest reading obtained NOTE There may be several places on the door where this procedure needs to be done If so start out with a fresh wat
64. ions to reduce the risk of burns electric shock fire injury damage to oven or property near oven or possible exposure to excessive microwave energy General Safety Information Y Read all instructions before using this appliance Y Read and follow the specific Precautions to be Observed Before and During Servicing to Avoid Possible Exposure to Excessive Microwave Energy found on page ii v This appliance must be grounded Connect only to properly grounded outlet See Grounding Instructions found on page ii Y Install or locate this appliance only in accordance with the provided installation instructions v Some products such as whole eggs and sealed containers e g closed glass jars may explode and should not be heated in this oven v Use this appliance only for its intended uses as described in this manual v This appliance should be serviced only by qualified service personnel Contact the nearest authorized service facility for examination repair or adjustment Y Keep cord away from heated surfaces Y Liquids such as water coffee or tea are able to be overheated beyond the boiling point without appearing to be boiling Visible bubbling or boiling when the container is removed from the microwave oven is not always present THIS COULD RESULT IN VERY HOT LIQUIDS SUDDENLY BOILING OVER WHEN THE CONTAINER IS DISTURBED OR A UTENSIL IS INSERTED INTO THE LIQUID x DO NOT allow children to use this appliance x DO NOT use corrosiv
65. k Switch Monitor 102012 Screw 4 40 x 1 PPH Sems 102903 qty 2 6 Interlock Switch Secondary 102012 Screw 4 40 x 1 PPH Sems 102903 qty 2 7 Mounting Bracket Interlock Switch 15 9272 Screw 10 32 x 3 4 lg PPH Sems Int Th 102937 qty 2 8 RTD Cook Cavity HHC 6517 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 2 NOTE For more interlock switch detail see Figure A 11 page A 13 SLNINOdWOD NJAO ONIDVId38 XIGNAddV A 12 APPENDIX REPLACING OVEN COMPONENTS Replacing Items Removing Opening Multiple Covers Required Figures A 10 A 11 A A A DANGER Before replacing any oven component ensure the oven is removed from any power source Replacing a component while the oven is plugged in can result in serious injury or death CAUTION Before removing installing any component make sure it is disconnected from the wire harness where applicable NOTE Hardware listed is required for installing component to oven To remove the left side cover see page A 9 To remove the right side cover see page A 11 To open the top cover see page A 5 GE Item Description Item Part Number Hardware Description Hardware Part Number s 1 Hinge Bracket Slide LHS 15 9196 Nut Keps Hex 8 32 Ext Tooth Cres 102962 qty 4 2 Hinge Bracket Slide RHS 15 9195 Nut Keps Hex 8 32 Ext Tooth Cres 102962 qty 4 3 Hinge C
66. n in EDIT MODE see page 14 field 2 Access the Food Group screen page 20 3 Select a recipe to edit Figure 24 7 Use the number keys to adjust the cook time 4 Use the Down key to move the cursor to the 8 Press the R3 soft key to save changes desired Event Setting field Figure 25 NOTE For the save to take effect the cursor must NOTE To help make navigation easier the be advanced past the field that was last edited currently selected field will be displayed in the top right corner of the display In Figure 25 the 9 If desired press the R5 soft key to test cook cursor is in the TIM column the new settings In doing so the oven may require additional warmup time 5 Use the number keys to adjust event settings 10 When all editing is complete return to the Time 0 100 in 1 increments The Options screen and turn off the EDIT MODE sum of the percentages across eight events see page 14 This will allow access into the must equal 100 regular cook mode Top Blower 10 100 in 10 incr Bottom Blower 10 100 in 10 incr Microwave 0 100 in 10 incr JaAONW 1103 22 EDITMODE This page intentionally left blank Oven Systems 23 Convection System The convection system is designed to rapidly heat clean and recirculate air into the cook cavity This section contains information about the following components Blower motor bottom Blower motor top
67. n interior A CAUTION DO NOT spray oven cleaner into the perforation on the back oven wall Doing so can damage critical oven components resulting in a non warranty service call JDNVNALNIVW AIYA Allow Oven Cleaner to penetrate stains for five minutes Clean the oven interior with a nylon scrub pad DAILY MAINTENANCE Step 7 Clean and Dry the Oven Door A CAUTION DO NOT spray oven cleaner directly onto the oven door gasket reference A in adjacent photo or saturate it with water A CAUTION DO NOT scrub or attempt to clean the oven door gasket Doing so may cause the oven door to misalign resulting in a non warranty service call Clean oven door with oven cleaner and a nylon scrub pad Wipe the oven door with a damp towel Step 8 Rinse the Oven Interior A CAUTION DO NOT use a hose or water jet for cleaning Doing so can damage critical oven components resulting in a non warranty service call Rinse the oven interior with clean water Dry the oven interior with a clean towel Step 9 Apply TurboChef Oven Guard Spray Oven Guard onto a clean towel Wipe the oven s interior walls and the inside of the oven door A CAUTION DO NOT apply Oven Guard to the oven door gasket Doing so may damage the gasket resulting in a non warranty service call Step 10 Reinstall Components Reinstall the lower air diverter Reinstall the lower jetplate Screw in the two thumb screws to lock the lower je
68. nce table to determine if the transformer is OK If the resistance is different then the table indicates replace the transformer High Voltage Diodes The high voltage diode Figure 29 is assembled by connecting several 1000 1500 volt semi conductor diodes in a series to increase the reverse voltage capability In the circuit the high voltage diode conducts to prevent the filament voltage from becoming positive thus as the high voltage winding of the transformer goes to 2400 VPK the high voltage capacitor is charged to 2400 volts Figure 29 High Voltage Diode High Voltage Transformers Primary Voltage Frequency Taps and Resistance Secondary Taps and Resistance NGC 3062 1 208 VAC 60 Hz 1 amp 2 0 819 1 001 Q 240 VAC 60 Hz 1 amp 3 0 972 1 188 Q 4 Ground 53 60 65 52 Q NGC 3062 2 230 VAC 50 Hz 1 amp 2 0 972 1 188 Q 3 Ground 57 52 70 30 Q NGC 3062 3 200 VAC 50 60 Hz 1 amp 2 0 784 0 958 Q 3 Ground 55 75 68 13 Q Filament Transformers Primary Voltage Frequency Taps and Resistance Secondary Taps and Resistance 15 70 19 18 Q NGC 3061 1 208 VAC 60 Hz 1 amp 2 4 5 very low resistance if read 17 49 21 37 Q ing is open transformer has failed 240 VAC 60 Hz 1 8z 3 20 61 25 19 Q NGC 3061 2 230 VAC 50 Hz 1 amp 2 3 4 very low resistance if read 18 99 23 21 Q ing is open transformer has failed NGC 3061
69. nd keypad remain on Happens When The oven completes MODE 10 Goes To MODE 2 when On Off key is pressed INFO MODE page 13 when Info key is pressed Mode 2 Temperature Select NOTE If cooking with only one temperature this screen will be bypassed The i5 Oven can store up to four different cook temperature settings Each temperature setting has 5 food groups assigned to it each consisting of 10 food recipes 50 recipes per temperature setting NOTE Earlier i5 software versions store only two temperatures each containing 100 food recipes The operator will be able to cook only recipes associated with the selected temperature setting See Edit Mode page 19 for more information on using and changing multiple temperatures To select a temperature if applicable press the adjacent soft key Happens When The On Off key is pressed from MODE 1 The Back key is pressed from MODE 3 Goes To MODE 3 when a temperature is selected MODE 1 or 10 if the On Off key is pressed Mode 3 Warming Up Mode during which the oven warms to the pre set cook temperature Happens When A temperature is selected from MODE 2 if multiple temperatures are present On Off key is pressed from MODE 1 or 10 if single temperature is present Goes To MODE 4 when the oven temperature reaches the selected set temperature if the oven temperature needed to recover more than 125 F 70 C at
70. ntercom wires microphone wires speaker cables etc away from the oven Specifications and Installation I oT 33 N D wo 1 eo e f Figure 1 i5 Oven Dimensions Theory of Operation The i5 rapid cook oven combines precisely controlled impinged air and microwave energy to create higher heat transfer rates than conventional ovens Top launched microwave and impinged air are stirred to further ensure even heat distribution while impinged air enters the cavity from the top and bottom generated by dual independently controlled blower motors The combination of this technology with the size of the cook cavity allows for higher throughput than other batch ovens This manual includes instructions for servicing troubleshooting installing cleaning and operating the i5 oven If you have questions that are not addressed in this manual contact Technical Service 800 90TURBO 1 214 379 6000 or your Authorized Distributor Certifications cULus UL EPH TUV CE FDA Dimensions Oven Dimensions Height 24 3 618 mm Width 27 2 691 mm Depth door closed 28 25 718 mm Depth door open 43 4 1102 mm Weight 275 lbs 125 kg Cook Cavity Dimensions Height 10 254 mm Width 24 610 mm Depth 16
71. ompted enter the password 9 4 2 8 and press the Enter key From TEST MODE the oven s components can be tested independently or a comprehensive selective self test can be run Unless otherwise specified idle airflow is set to 10 and the stirrer motor is turned on Top Blower Press the L2 soft key to increase top blower speed in 10 increments NOTE While the top blower is being tested the bottom blower remains at 10 idle airflow Bottom Blower Press the L3 soft key to increase bottom blower speed in 10 increments NOTE While bottom blower is being tested the top blower remains at 10 idle airflow Heaters Press the L4 soft key to turn heaters on off NOTE When the heaters are not being tested make sure they are turned off otherwise the oven will overheat Magnetron Test Press and hold the L5 soft key to turn on the magnetrons To turn off the magnetrons simply let go of the L5 soft key Stirrer Press the R1 soft key to turn the stirrer on off TEST MODE FAULT LOG STIRRER ON TOP BLOWER 10 DIAGNOSTICS OFF BOTTOM BLOWER 20 MANUFACTURING MODE HEATERS ON SELF TEST MAG OFF PSM t BBUW Figure 14 Test Mode 15 Test Mode Status Indicators Figure 14 The status indicators are located at the bottom of the TEST MODE screen and consist of P Primary switch backlit open S Secondary switch backlit open M Monitor switch backlit open t Magnetron the
72. outside of the dish requires more browning or crispness Select cook and brown more if both the inside and outside of the dish are not done Select save time to save any change to the cook time made during MODE 6 Note that this option is not available if MODE 6 is disabled Select exit to return to the food group selection screen Cook More mode can be enabled disabled from the Options menu see page 14 It is disabled by default Happens When A cook cycle completes Goes To MODE 7 if one of the Cook More options is selected MODE 5 if Save Time is selected Exit is selected or if nothing is selected after 10 seconds MODE 10 if the On Off key is pressed Mode 10 Cooling Down Mode during which the oven blows cool air into the cook cavity to return it to room temperature Happens When The On Off key is pressed from MODES 2 6 8 or 9 Goes To MODE 1 when the oven temperature recedes below 150 F 66 C INFO MODE page 13 when the Info key is pressed 13 Overview of the Info Mode The INFO MODE serves four main purposes 1 To display oven information 2 To provide access to TEST MODE and additional diagnostic tools for service technicians 3 To turn oven options and features on off 4 To update oven settings To access the INFO MODE simply press the Info key when the oven is either off or cooling down The INFO MODE consi
73. re should be done while oven is hot As a result exercise extreme caution when adjusting the door 1 Ensure the oven door is closed 2 Remove the two 1 4 20 bolts securing the door hinge to the oven Figure 26A page 25 3 Allow the oven to warm up to the set temperature If more than one set temperature is present select the highest 4 If the oven will not warm up because the switches are misaligned as a result of the oven door slide the switches or switch bracket accordingly until each switch is engaged 5 Reference Figures 26B and 26C page 25 to determine where to tap If following Figure 26C remove the primary secondary and monitor switches before adjusting the door 6 Gently tap the oven door in the areas marked in Figures 26B or 26C until the door is parallel to the oven frame 7 Ifthe switches were removed reinstall them 8 From TEST MODE check the status indicators P S and M to verify the switches open and close in the correct sequence P S M when the door is open and M S P when the door is closed If they do not adjust the switches per the instructions on page 26 9 Perform a MW Leak Test page 27 Figure 26A Properly Adjusted Door TT Tap in this gt 0 corner Oven Frame Oven Frame Remove Remove Bolts Bolts T A Switches P u T Oven Door Hinge Hinge Oven Door Side Views TT D Tap in this corner Figure 26B Door Misaligned Variation 1
74. re the oven is used by the customer However if incoming voltage for the store is different than the preset voltage the operator will be required to select either 208 or 240 after pressing the On Off key to turn on the oven The correct voltage will be enlarged on the screen identifying which option to select see Figure 3 below SELECT VOLTAGE 208 VAC 240 VAC Figure 3 Selecting Voltage Counter Top Table Partition 24 3 618 mm Partition Above Counter Top WAN 24 3 618 mm Above Counter Top TurboChef Grill i5 Oven Deep Fryer 6 12 152 mm L 305 mm Minimum Minimum Figure 4 Installation Near Open Heat Source 32 0 813 mm rg 27 8 706 mm 26 625 676 mm Figure 5 Oven Cart Dimensions NOILVTIVLSNI ANY SNOLLVDI4ID3d4S 6 SPECIFICATIONS AND INSTALLATION This page intentionally left blank Daily Maintenance Daily Maintenance Supplies and Equipment The following steps will help maintain your i5 Oven TurboChef Oven Cleaner Part Number 103180 Use only TurboChef Oven Cleaner and Oven Guard TurboChef Oven Guard Part Number 10
75. reen 1 of the INFO MODE press the R3 soft key to view the fault log Figure 10 To view a detailed log of each fault occurrence Figure 11 press the soft key adjacent to the fault code Viewing the Service Numbers From screen 1 of the INFO MODE press the R4 soft key to view the phone numbers for TurboChef Technical Support FAULT LOG F1 BLOWER 8 F6 EC OT 0 F2 LOW TEMP 0 F7 RTD OPEN 0 F3 MAG C LOW F8 HX RISE LOW W F4 MONITOR F5 MAG OT Figure 10 Fault Log F1 FAULT DETAIL 12 04 07 20 18 09 26 07 17 42 07 18 07 14 35 07 15 07 08 36 07 14 07 22 07 07 14 07 13 54 07 14 07 05 22 4 MORE 4 DONMOOD ANY S1OY LNOD NJAO Figure 11 Fault Detail Info Mode INFO MODE Resetting the Oven Resetting the oven is one way to potentially clear an error message should one occur From screen 1 of the INFO MODE press the R5 soft key Turning Oven Options On Off Figure 12 From screen 2 of the INFO MODE press the L2 soft key to access the Options screen When prompted enter the password 9 4 2 8 and press the Enter key From the Options screen the following oven options can be turned on or off Adjust Time screen page 11 for more details Cook More screen page 12 for more details Edit Mode page 19 for more details Load Menu screen page 17 for more details Demo Mode TurboChef use only DHCP TurboChef use only Setting the Language NOTE Not availa
76. rmostat backlit open H Heaters backlit on B Bottom blower backlit on T Top blower backlit on W Microwave backlit on In Figure 14 All three door switches are engaged closed The heaters are on Both blower motors are on Microwave is not being used Test Mode Fault Log Press the L1 soft key to access the fault log This fault log is identical to the one accessible from screen 1 of the INFO MODE page 13 except on this screen pressing the 0 key clears all faults Test Mode Turning On Off Diagnostic Mode Press the R2 soft key to place the oven in DIAGNOSTIC MODE When in DIAGNOSTIC MODE the oven displays additional cooking parameters during a cook cycle including Event currently being cooked Time left per event wave top air bottom air Status indicators Group and recipe name CC temperature CC set point For normal oven operation ensure DIAGNOSTIC MODE is turned off AGOW ON 16 INFO MODE Test Mode Self Test From TEST MODE press the R4 soft key to access the Self Test screen Figure 15 From the Self Test screen LI soft key initiates a comprehensive self test The oven will check the door switches blowers magnetrons and heaters in sequence L2 soft key initiates a door switch test only L3 soft key initiates a blower test only LA soft key initiates a magnetron test only L5 soft key initiate
77. rness The wire harness distributes power to the oven s electrical components See page 51 for a schematic Troubleshooting Potentially any fault may occur in relation to the control system See section Fault Code Troubleshooting pages 39 44 Potentially any one of the issues diagnosed in the section Non Fault Code Troubleshooting may occur in relation to the control system See section Non Fault Code Troubleshooting pages 45 49 SWALSAS NJAO OVEN SYSTEMS Filtering System This section contains information about the following components Catalytic converter Drain pan Air Filter Vent catalyst Catalytic Converter The catalytic converter a VOC type catalyst is located behind the inside cook cavity wall and is responsible for cleaning the recirculating airflow The catalyst functions by substantially lowering the combustion temperature of grease entrained in the air path to approximately the same temperature of the airflow thus the grease burns and breaks down into CO and H O as it passes through the catalytic converter The catalyst will operate most efficiently at temperatures above 475 F 246 C The catalyst material is very sensitive to certain chemical compounds Irreversible damage can occur if the catalyst is exposed to cleaning chemicals containing phosphates NaOH silicates Na and Potassium Salts These chemicals are found in most commercial degreasers and cleaners th
78. s a heater test only When each test completes the oven will display PASS or FAIL Test Mode Manufacturing Mode Press the R3 soft key to place the oven in MANUFACTURING MODE Figure 16 When in MANUFACTURING MODE the following tests and settings can be accessed Microwave leakage test Microwave power test AUTO TEST See DOOR TEST BLOWER TEST MAG TEST HEATER TEST KEE Figure 15 Self Test MANUFACTURING MODE MW LEAKTEST SELF TEST MW POWER TEST SETPOINT 500F BURN IN SERIAL NUMBER EDIT FAHRENHEIT ERASE DEFAULT Figure 16 Manufacturing Mode Burn in Serial number edit Temperature measurement F or C Self test same as TEST MODE Erase default oven settings Microwave Leakage Test Press the L1 soft key to initiate the microwave leakage test The oven will warm up to 500 F 260 C When warmup is complete insert the water load Follow the steps on page 27 Microwave Power Test This test should only be performed by the manufacturer Burn In Press the L3 soft key to initiate a 25 minute burn in This feature helps ensure all cavity walls reach ther mal equilibrium before testing is conducted SERIAL NUMBER EDIT i5 D10001 CANCEL Figure 17 Serial Number Edit ERASE SETTINGS ERASE COUNTERS AND FAULT LOGS COMPLETE ERASE Figure 18 Erase Settings Serial Number Edit Press the L4 soft key to access the Edit Serial Number screen To edit t
79. s appliance must be grounded In the event of an electrical short circuit grounding reduces the risk of electric shock by providing an escape wire for the electric current This oven is equipped with a cord that has a grounding wire with a grounding plug which must be plugged into an outlet that is properly installed and grounded Consult a qualified electrician or serviceman if uncertain about the ability to follow grounding instructions or if doubt exists as to whether the appliance is properly grounded x DO NOT use an extension cord If the power cord is too short have a qualified electrician or serviceman install an outlet near the appliance N WARNING Improper grounding can result in risk of electric shock Power Cord Replacement If the power cord is damaged it must be replaced by the manufacturer its service agent or a similarly qualified person Precautions to be Observed Before and During Servicing to Avoid Possible Exposure to Excessive Microwave Energy a DO NOT operate or allow the oven to be operated with the door open b Make the following safety checks on all ovens to be serviced before activating the magnetron or other microwave source and make repairs as necessary 1 interlock operation 2 proper door closing 3 seal and sealing surfaces arcing wear and other damage 4 damage to or loosening of hinges and latches 5 evidence of dropping or abuse c Before turning on microwave power for any service tes
80. se F2 12 amp 100592 None None 4 Fuse F3 12 amp 100592 None None 5 Fuse F4 12 amp 100592 None None 6 Fuse Holder 103548 Screw 8 32 x 3 8 PPHD Int Sems SS 102921 qty 4 7 Heat Shield Support Bracket 15 9224 Screw Torx Head Sh Mtl 3 8 Cres 102752 qty 2 8 Keypad 15 9247 None None 9 Power Supply 101211 Screw M3 x 8mm Sems PPHD Cres 103444 qty 3 10 Power Supply Bracket 15 9280 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 2 11 Relay K1 Filament 101273 Nut Keps Hex 6 32 Ext Tooth Cres 102961 qty 2 12 Relay K2 Anode 101273 Nut Keps Hex 6 32 Ext Tooth Cres 102961 qty 2 13 Relay K3 Monitor 101273 Nut Keps Hex 6 32 Ext Tooth Cres 102961 qty 2 14 Relay K6 Voltage 101272 Nut Keps Hex 6 32 Ext Tooth Cres 102961 qty 2 15 Relay K7 Mag Fan 101273 Nut Keps Hex 6 32 Ext Tooth Cres 102961 qty 2 16 Relay K8 Stirrer 101273 Nut Keps Hex 6 32 Ext Tooth Cres 102961 qty 2 17 Relay Bracket 15 9261 Screw 8 x 3 8 PH Mod Truss Cres 101682 qty 4 18 Relay Solid State K4 K5 Heaters 101286 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 2 NOTE Additional keypad detail on Figure A 6 page A 8 Replacing Items Removing Top Cover Required Figures A 4 A 5 A 6 A DANGER Before replacing any oven component ensure the oven is removed from any power source Replacing a component while the oven is plugged in can result in serious injury or death
81. setting Think of each temperature as a block of 5 food groups or 50 recipes The table below outlines differences between the two modes in more detail NOTE Earlier i5 software versions store only two temperatures each containing 100 food recipes Single Temperature Mode Multiple Temperature Mode Edit Mode Four temperatures available to edit Same as single temperature mode Figure 22 page 20 Adjacent soft key to access recipes Same as single temperature mode associated with temperatures Figure 22 page 20 When in group select Figure 23 When in group select Figure 23 page page 20 all 200 recipes will be 20 only recipes associated with the available to edit because all selected temperature will be available to temperature settings are identical edit NOTE if additional temperature settings are identical to the one that was selected the associated recipes for those temperature settings will also be available to edit Temperature displayed adjacent to Same as single temperature mode each block of five food groups Figure 23 page 20 Cook Mode No temperature selection screen The When the oven is turned on select a oven automatically warms up when temperature before warming up Figure the On Off key is pressed Figure 7 2 page 10 7 3 page 10 Number of Recipes 200 all If 2 unique temperatures 100 100 or Available to Cook 150 50 If3
82. sts of two screens To toggle between screens press the Up key or Down key From screen 1 of the INFO MODE Figure 8 View the oven serial number View the oven software version View the menu part number and revision View the last temperature selected to cook View the electrical compartment temperature View the cook counter total cook time magnetron time and total oven on time View the operating voltage North America models only Access the fault log Access service phone numbers Reset the oven S N i5 DXXXXXX COOKS 257 SOFTWARE VERSION 208 VAC INFO 1 MENU P N AND REV FAULT LOG LAST COOK 500F SERVICE NUMBERS ELECTRICAL 84F RESET OVEN Figure 8 Info Mode Screen 1 TEST MODE LOAD MENU SET OPTIONS SET LANGUAGE SET DATE TIME Figure 9 Info Mode Screen 2 From screen 2 of the INFO MODE Figure 9 Access TEST MODE Access the Options screen Set the language not available on all models Set the date time Access the Load Menu screen Viewing Cook Counter Time Logs From screen 1 of INFO MODE press the R1 soft key Once to display the cook counter Twice to display total cook time Three times to display total magnetron time Four times to display total oven on time Viewing the Fault Log Figures 10 11 This log is read only To zero the fault counters see page 15 For more information on faults see pages 37 38 From sc
83. t 15 9165 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 4 14 Shunt Plate Assembly 15 9307 Screw 6 32 x 38 PFH 100 Deg SS 101430 qty 9 DS so oo a 16 Vent Catalyst Foil Pack RWD 9191 None None 17 Vent Tube Cover 15 9209 Screw 6 x 1 2 PPHD Drill Point SS 101687 qty 2 18 Weldment Heat Chnl Vent Tube NGC 1397 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 6 Figure A 1 No Cover Removal Required Figure A 2 Door Assembly Detail Figure A 3 Opening Top Cover Required Replacing Items Opening Top Cover Required Figure A 3 A DANGER Before replacing any oven component ensure the oven is removed from any power source Replacing a component while the oven is plugged in can result in serious injury or death A CAUTION Before removing installing any component make sure it is disconnected from the wire harness where applicable IN NOTE Hardware listed is required for installing component to oven To open the top cover 1 2 Open the oven door The top cover is secured to the heat shield via 2 sheet metal screws above the oven door Remove these screws Open the top cover Secure the support arms in place A 5 SLNINO4IWOD NJAO DNIDV 1434 XIGNAddV A 6 APPENDIX REPLACING OVEN COMPONENTS 1 Cover Top 15 9243 Screw 10 32 x 3 8 lg PFLH 100 Deg SS 1101401 qty 2 2 Fuse F1 12 amp 100592 None None 3 Fu
84. t 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 manual before the oven is released to the owner e A microwave leakage check to verify compliance with the Federal Performance Standard should be performed on each oven prior to release to the owner RF Interference Considerations The i5 oven generates radio frequency signals This device has been tested and was determined to be in compliance with applicable portions of FCC part 18 requirements and to the protection requirements of Council Directive 89 336 EEC on the approximation of the laws of the Member States relating to electro magnetic compatibility at the time of manufacture However some equipment with sensitivity to signals below these limits may experience interference If your equipment experiences interference Y Increase the physical separation between this oven and the sensitive equipment v If the sensitive device can be grounded do so following accepted grounding practices v If battery powered microphones are being affected ensure that the batteries are fully charged Y Keep sensitive equipment on separate electrical circuits if possible Y Route i
85. ter Balance Assembly The door hinges and counter balance assembly work to ensure the door consistently opens and closes smoothly Adjusting the Counter Balance Assembly WARNING Procedure requires work while the oven is hot As a result exercise extreme caution when adjusting the door switches NOTE In Figure 27 some oven components have been removed for clarity The adjustment procedure MUST be performed with the counter balance and hinges installed 1 Ensure the oven door is closed 2 Remove both side panels 3 Remove both switch bracket assemblies one on each side of the oven See Figure 27 4 Remove the door hinge gussets from each side of the oven See Figure 27 5 On one side of the oven loosen the screw as shown in Figure 27 6 Slide the adjustment spacer included with counter balance assembly kit under the counter balance bracket The thin side of the spacer should go between the screw and the bracket and the notch should rest against the side of the bracket See Figure 27 7 Tighten the screw against the adjustment spacer so that the spacer cannot slide out 8 Loosen the screw just enough to allow the spacer to slide out 9 Repeat steps 5 8 for the other side of the oven 10 Reinstall the door hinge gussets and ensure the bolts are snug 11 Reinstall the switch bracket assemblies verifying that the levers on the switches are in the closed position i e snug against the actuator
86. tion of the trail ing arm When the door closes does the trailing arm engage the switches NO t Ha NO Is F4 MONITOR fault present YES Refer to trouble shooting procedures on page 42 Loosen the two switch bracket screws With the door closed position the bracket so that the trailing arm is just engaging the switch levers Open and close the door Are door switches freely opening and closing Is the wiring from the door switches to control board OK YES Adjust the counter balance assembly page NO 126 Is issue resolved gt YES YES y Tighten the switch bracket Screws Replace the door switch es page A 9 through A 11 NO Y Correct wiring If wiring is damaged replace door switch es page A 9 through A 11 45 DNILOOHSFIANOUL 46 TROUBLESHOOTING Troubleshooting No Display Screen is Blank YES Does the keypad beep when Y a key is pressed Replace the fuses page A 5 through A 6 Is wiring from the control board to the display OK La NO L No Correct wiring If ribbon cable is damaged replace the keypad page A 5 YES y through A 6 Replace the power supply page A 5 Is pin 1 on the J7 connector receiving 5 VDC see schematic page 51
87. tplate in place Reinstall the wire rack Close the oven door Step 11 Clean the Drain Pan Remove the drain pan entirely from the bottom of the oven Wipe down the inside of the area the drain pan fits within Empty clean and reinstall the drain pan A CAUTION Ensure the drain pan s outer edge is flush with the door panel i e not sticking out Failure to do so will damage the oven door resulting in a non warranty service call Step 12 Clean the Oven Exterior Wipe the oven exterior with a clean damp towel A CAUTION DO NOT spray chemicals into any openings such as the louvers on the side panels or the rear vent catalyst housing Doing so can damage critical oven components resulting in a non warranty service call Step 13 Clean the Air Filter once a week Remove the air filter from the back panel Wash in dishwasher or rinse with hot water DO NOT use a water jet Doing so will shorten the life of the filter Reinstall the air filter A CAUTION DO NOT operate the oven without the air filter in place Oven Controls and Cooking Figure 6 Oven Controls Oven Controls 1 Info Key When the oven is off or cooling down press to access the INFO MODE see page 13 2 On Off Key When the oven is cooling down or off press to turn on the oven When the oven is on or warming up press to turn off the oven When the oven is in the INFO MODE see page 13 press to return the oven to the
88. ubleshooting F8 HEAT LOW SE YES Are bath blower motors moving air NO Check in TEST MODE see page 15 Is the nigh ran NO Is the heater defective Check in See page 39 thermostat tripped TEST MODE see page 15 ic troubleshoot F1 BLOWER Blower Running Status Bad YES YES NO y 1 i Is the solid state relay Reset page 34 and Replace defective defective or damaged heater page A 11 determine why it tripped excess Verify the solid state grease buildup etc relay is not shorted across output YES NO i Replace the solid state relay Is the wiring from the solid page A 5 through A 6 state relay to the control board OK See page 51 for schematic YES NO y Y Replace the control board page A 8 Correct wiring Non Fault Code Troubleshooting This section provides troubleshooting tips for issues that may occur independently of an oven fault Troubleshooting No Keypad Input YES Is the keypad cable properly connected to the Replace the keypad page A 5 through A 6 If the problem persists replace the control board page A 8 control board Correct wiring Troubleshooting Cook Door Open Message when Door is Closed Verify the ac

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