Home

TurboChef Service Manual

1. SAFETY INTERLOCKS BLI50 PRIMARY INTERLOCK 28 K6 VOLTS 1 08270 NC a 98 7 MONITORSWITCH LA 2 4 BR280 DD ge 2 08440 INTERLOCK 7 ITO SUPPLY prazo 8 BR450 NC o C 3 08360 o NO 47725 BL370 sab 8 HV TRANSFORMERS E mae 1 2 208VAC CT q 1 3 240VAC p t cc b 8 BL355 3 2 2 K3 __ 2 TI BR400 Y Y Y Y Y Y Y Y i e 3 4 4 2 g 3 6 M2HV MIHV 3 26 4 MAG THERMO 5 EA M2FC 6 085 OR 6 SWITCHES A B MIFC FT2 OF 7 ORT ie j 4 2 0 93 uF 0 93 u
2. smm _______ PRIMARY INTERLOCK KG VOLTS EE mu onzro d MONITOR SWITCH em I zvoc F 4 od y Power 2 SECINTERLOCK SUPPLY 2 MET E E sE a acus ey HV TRANSFORMERS 8 de 208vkC En Er z 1 2 240VAC i A E a 5 1 14000000001 7 MAG Xx MAG OUT ST MAG THERMO win 5 an une motor wo renin o Es E PRIMARY ND INTER IN zn SECONDARY NO INTER IN aa Msc 2 STATUS OX sel aset 4 Ti was ens i 226 3 E MIL our MoDUAL IN at Bs lur ia ih Ga a s 5 m 415 gas Coons Ic zav pas INTER CN A MONITOR RTN 2 FAN i2 208AC 24V MAG T
3. Washer Splitlock 1 4 CRES Screw PFLH 1 4 20 x 1 2 Lg 100 Cres Nut Hex 10 32 Ext Tooth Keps CRES Washer Flat 1 4 Cres Screw 8 32 x 3 8 Int Tooth Keps CRES Key Woodruff Steal Spacer Blower Insulation Heat Shield Blower Motor Insulation Blower Plate Set Screw Skt Hd 10 32 x 5 16 CRES SERVICE PARTS AND ILLUSTRATIONS 63 FIGURE 34 IR ELEMENT AND CATALYTIC CONVERTER PARTS AND ASSEMBLY Chapter 8 IR Element and Catalytic Converter Page 48 136 IR Element and Catalytic Converter Parts 130 101312 Snap Ring 134 101688 Screw 8 x 1 2 Sht Metal PTH 131 102477 Washer Shim 135 NGC 1030 Clip Catalytic Converter 132 100649 IR Element 136 NGC 1012 Catalytic Converter 133 NGC 1116 Shield Microwave 64 SERVICE PARTS AND ILLUSTRATIONS FIGURE 35 NGC TORNADO SCHEMATIC P N NGC 1070 Chapter 9 Schematic and Schematic Parts Inside the fold out of page 49 Part list to the right SAFETY INTERLOCKS
4. Item 10 not shown for clarity I7 I8 THE CONTROL SYSTEM CONTROL SYSTEM TROUBLE SHOOTING ISSUE RESOLUTION No Display Blank 1 Verify power 208 VAC or 240 VAC is going to the oven correctly If not correct the voltage supply 2 Control DOES NOT beep when any Key on the Keypad is pressed Check power going to the 24VDC Power Supply Supply must have 208 or 240 VAC across L and N terminals If there is No Voltage Change F1 and F2 Fuses If the Voltage is OK Verify output of Power Supply is 24 VDC If there is no Output change the Power Supply If the Power Supply is 24 VDC see below Output is 24VDC Verify I O Control Board has 24 VDC by checking the voltage on the D6 Diode striped end on the I O Control Board to Chassis Reference page 50 for a schematic of the I O Control Board No Voltage Check wires from Power Supply to I O Control Board Voltage is 24VDC but 5VDC is not present on the I O Control Board J3 connector Change I O Control Board 3 The control DOES beep when any Key on the Keypad is pressed Check all connections between the I O Control Board and Display Correct any loose connections If connections are OK and 5 VDC is present on the J3 connector but there is still no Display change Display No Keypad Input 1 Check Keypad Ribbon Cable going to the I O Control Board Cable and Connection Bad Replace Keypad Cable and Connection OK Replace the
5. ese d LA LATCH TOGGLE TO BE LEVEL OR NEARLY LEVEL SWITCH GAP 0 02 FIGURE 27 DOOR SWITCH ASSEMBLY AND PARTS Chapter 6 The Cook Door Page 36 Door Switch Parts 59 NGC 1072 60 102012 61 NGC 1087 62 NGC 1073 63 101119 64 100059 Bracket Latch Switch Micro 0 1A 125VAC Spring Door Latch Toggle Latch Pin Clevis 93 16 x 1 Lg Bearings Bronze 3 16ID x 5 1GOD x 1 4 Lg 65 101557 66 102921 67 NGC 1126 68 100639 79 101296 SERVICE PARTS AND ILLUSTRATIONS Screw 4 40 x 1 25 Lg PPHD CRES Screw 98 32 x 3 8 Internal Tooth Sems PPHD SS Plate Door Switch Grease USDA H 1 Food Grade Ring Eclip 97 58 SERVICE PARTS AND ILLUSTRATIONS FIGURE 28 MOTOR SWITCH ADJUSTMENT AND ASSEMBLY Chapter 6 The Cook Door Page 37 N loe Monitor Safety Switch Parts 70 102804 Hinge Right 73 101912 Standoff 8 32F Fx1 in S 71 102012 Switch Limit Micro 74 102921 Screw 48 32 x 3 8 72 NGC 1126 Plate Door switch 75 102902 Screw 4 40 x 5 8 FIGURE 29 COOK DOOR ASSEMBLY Chapter 6 The Cook Door Page 38 Cook Door Parts 76 NGC 1151 77 NGC 1056 78 NGC 1057 79 NGC 1059 80 NGC 1061 81 NGC 1062 82 102750 83 NGC 1076 002 84 NGC 1132 85 102945 86 NGC 1138 Assy
6. WARNING Do not attempt to measure these voltages MAGNETRON VOLTAGE B A 4800 V C 2400 LAN A E 2400 Current a0 Y Flow NES Loco CHARGED CAPACITOR PLUS TRANSFORMER ON NEGATIVE VOLATAGE SWING MICROWAVE SYSTEM PARTS Figure 15 11 102101 High Voltage Transformer 2 12 102101 High Voltage Transformer 1 13 100201 High Voltage Capacitor 2 14 100201 High Voltage Capacitor 1 15 100481 High Voltage Diode 2 16 100481 High Voltage Diode 1 17 102102 Filament Transformer 2 18 100083 Mag Cooling Fan 19 101271 K3 Monitor Relay 20 101271 K2 High Voltage Relay 21 101271 K1 Filament Relay 22 102102 Filament Transformer 23 100599 F3 Fuse 20 Amp 24 102070 Mag 2 Thermostat 25 100861 Magnetron 2 26 NGC 1106 Wave Guide 2 27 102070 Mag 1 Thermostat 28 100861 Magnetron 1 29 NGC 1044 Wave Guide 1 FR NS AS A Bi T FR Ney H SN FIGURE 15 Microwave System Parts Figure 16 30 100861 Magnetron 31 102070 Magnetron Thermostat 32 NGC 1163 Insulator Adhesive 33 100186 Screw 6 Sheet Metal 34 100186 Magnetron Wire MI
7. L2 SERVICE PARTS AND ILLUSTRATIONS 6 FIGURE 32 CONVECTION CIRCUIT ASSEMBLY AND PARTS Chapter 7 Convection Circuit Page 42 Convection Circuit Parts 97 101688 Screw 8 x 1 2 PTH 102 100661 Heater Convection 98 NGC 1081 Cover Motor Cap 103 100443 Controller Motor 99 100905 Nut 1 4 20 Flange 104 101284 Relay K4 K5 SSR 100 NGC 1025 Assy Blower Motor 105 100592 Buss Fuses 12 Amp 101 101688 Screw 8 x 1 2 PTH 106 102075 High Limit Thermostat 62 SERVICE PARTS AND ILLUSTRATIONS FIGURE 33 BLOWER MOTOR PARTS AND ASSEMBLY Chapter 7 Convection Circuit Page 43 Blower Motor Parts 107 700 0306 2 Hub Small 108 NGC 1019 2 Fan Blade NGC Oven 109 NGC 1020 110 NGC 1021 111 700 0284 112 NGC 1024 113 100443 114 NGC 1023 115 102708 116 100882 117 100790 118 NGC 1022 119 101393 Ring Fan Blade Plate Blower Cap Shim Seal Sealing Block Blower Washer Wave Spring 30mmOD Clamp Blower Seal Heat Slinger Fan PM Motor Motor 1HP Flange Mount Aspen Loctite 272 Spacer Blower Motor Bolt Hex 1 4 20 x 3 4 Lg CRES 120 102400 121 101392 122 102963 123 102200 124 102921 125 100730 126 NGC 1122 127 NGC 1102 128 NGC 1123 129 101711 SIDE VIEW
8. Key to return to the Idle Mode Heater Test The Heater Key turns the heater On or Off If the heaters are On pressing the corresponding Soft Key turns the heaters Off If the heaters are Off pressing the Heater Key turns the heaters On If the Blower Speed is 0 the Blower Speed is set to the Idle Airflow FIGURE 6 Test Mode Screen 2 Magnetron The Key is a press and hold key to test the Magnetron If the Magnetron Filaments are Off when the MAG Key is pressed the message MAG Warming is displayed After a five 5 second delay or if the filaments are already On MAG Power is displayed The Magnetron should operate at this point Once the Key is released the high voltage supply is switched Off to the Magnetron and the Magnetron will stop radiating however the power is still supplied to the Magnetron Filaments and Magnetron Cooling Fan for an extra three 3 minutes Diagnostic Display The DIAG Key turns On or Off the Diagnostic Display feature This feature adds temperature displays to the Menu Group Screens While cooking the Cook Cycle parameters are displayed when diagnostics are enabled In addition the Status Indicators are displayed on the bottom of the screen When a Status Indicator is highlighted backlit the corresponding system associated with that Status Indicator is Off For example Bd would indicate that the Microwave Sys
9. Heat Slinger Fan PM Motor Motor 1HP Flange Mount Aspen Loctite 272 Spacer Blower Motor Bolt Hex 1 4 20 x 3 4 Lg CRES Washer Splitlock 1 4 CRES 121 101392 122 102963 123 102200 124 102921 125 100730 126 NGC 1122 127 NGC 1102 128 NGC 1123 129 101711 Assembly Notes THE CONVECTION CIRCUIT 43 SIDE VIEW Screw PFLH 1 4 20 x 1 2 Lg 100 Cres Nut Hex 10 32 Ext Tooth Keps CRES Washer Flat 1 4 Cres Screw 8 32 x 3 8 Int Tooth Keps CRES Key Woodruff Steal Spacer Blower Insulation Heat Shield Blower Motor Insulation Blower Plate Set Screw Skt Hd 10 32 x 5 16 CRES 1 115 to be located and installed as shown on shaft shoulder near the motor housing 2 Spacing between Item 108 and 110 must be 0 20 inches minimum See side view 44 THE CONVECTION CIRCUIT CONVECTION CIRCUIT TROUBLE SHOOTING ISSUE RESOLUTION F8 Heat Low 1 Check that the Blower Motor is moving air Blower Motor is not moving air Check Blower Motor Assembly Oven Not Warming Up and verify Motor is stalled Correct any issues with Motor Assembly See Figure 33 Blower Motor is moving Air Verify High Limit The
10. THE MICROWAVE SYSTEM How to check a Magnetron for Open Shorted Filament 1 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 22 3 An Ohmmeter connected between the Filament Terminals F FA should indicate a reading of less than 1 Ohm Figure 22 4 continuity check between either Filament Terminal and the Magnetron Chassis should indicate an infinite resistance open How to check a High Voltage or Filament Transformer 1 Disconnect all the wires in question going to the Transformer 2 Use an Ohmmeter to check the impedance of the Primary and Secondary Winding Refer to the High Voltage and Filament Transformer able below to determine if the transformer is OK If the resistance is different then the table indicates replace the Transformer HIGH VOLTAGE AND FILAMENT TRANSFORMER RESISTANCE TABLE DESCRIPTION P N PRIMARY 208 TAPS 1 amp 2 SECONDARY TAPS 4 amp GROUND Q PRIMARY 240 TAPS 1 amp 3 High Voltage Transformer 102101 0 882 1 08 1 06 1 29 53 64 65 56 Filament Transformer 102102 19 17 23 43 O 22 41 27 39 Q 0 088 0 108 0 29 30 THE MICROWAVE SYSTEM MICROWAVE SYSTEM TROUBLE SHOOTING ISSUE RESOLUTION F3 Magnetron Current Low 1 Check F3 Fuse Fuse OK Go to Step 2 Fu
11. TurboChef Service Manual FOR THE TURBOCHEF NGC TORNADO OVEN ETURBOCHES Accelerating the World of Cooking 800 90TURBO Part Number NGC 1007 Revision A July 23 2004 IMPORTANT SAFETY INFORMATION PLEASE READ FIRST WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death Read the installation operating and maintenance instructions thoroughly before installing or servicing this equipment This product employs an exposed radiant heating element on the bottom of the cavity This element is HOT during operation and will remain at dangerous temperatures after the unit is switched off NEVER attempt to touch the element during operation or while the oven is warm DO NOT store or use gasoline or any other flammable vapors or liquids in the vicinity of this or any other appliance The information contained in this manual is important for the proper installation use and maintenance of this oven Adherence to these procedures and instructions will result in satisfactory baking results and long trouble free service Please read this manual carefully and retain it for future reference Errors descriptive typographic or pictorial are subject to correction Specifications are subject to change without notice Table of Contents Important Safety Instructions Precautions to Avoid Possible Exposure to Excessive Microwave Energy Grounding Instructions RF Interfer
12. F2 LOW TEMP F3 MAG CURR F4 MONITOR F MAG TEMP F6 TEMP FIGURE 3 Fault Display F2 Cook Temperature Low Fault is displayed if the Cook Chamber Temperature is more than 84 F below the Set Temperature after five 5 seconds into a Cook Cycle The fault is cleared at the onset of cooking if the Cook Chamber Temperature is within 84 F of the Set Temperature or when the heater is tested in the Test Mode F3 Magnetron Current Low Fault is displayed when the Current Transformer CT on the I O Control Board does not detect enough current The Fault is monitored when the microwave is on during a Cook Cycle or Self Test The fault is cleared at the onset of a Cook Cycle if the CT detects current or when the magnetron is successfully energized in the Test Mode F4 Door Monitor Defective Fault is displayed when the Control detects that the Monitor Interlock Switch unlatches before both the Primary and Secondary Interlock Switches during a Cook Cycle In addition this fault will blow the F3 Fuse if the microwave high voltage system is energized when the fault occurs The fault is cleared only when the oven is turned Off and On FAULT CODES NOTE Door Interlock Switches are in parallel See Figure 35 on the inside of page 49 The fault is monitored during a Cook Cycle or Self Test when the Microwave is on F5 Magnetron Over Temperature Fault is displayed when the Thermostat on either Magnetron is
13. Open The fault is cleared at the onset of a Cook Cycle if the Thermostat is closed or when the Magnetron is successfully tested in the Test Mode F6 EC Electrical Compartment Temperature High Fault is displayed when the EC Thermocouple exceeds 158 F and is monitored once per minute The fault is cleared when the EC Thermocouples temperature is below the indicated limit FAULT CODE TABLE F7 Thermocouple Open Fault is displayed when the Control detects that either the IR or CC Thermocouple is Open n 999 F indicates the CC Thermocouple is Open a 1999 F indicates the IR Thermocouple is Open Fault is cleared when the control detects continuity on the open Thermocouple Circuit F8 Heat Low An Error Message not a Fault Code displayed during Warm up or Self Test if the Cook Chamber Temperature TCC fails to rise 14 F within thirty 30 seconds FAULT CODE AND DESCRIPTION WHEN ACTIVE REFER TO Warm up Idle Mode Cook Mode Self Test F1 Blower Running Status Bad X X X X Page 19 F2 Cook Temperature Low X Page 20 F3 Magnetron Current Low X X Page 30 F4 Door Monitor Defective X Page 36 F5 Magnetron Over Temperature X X Page 24 F6 EC Temperature High X X X Page 12 F7 Thermocouple Open X X X X Page 18 F8 Heat Low X X Page 44 Fault Codes are listed in order of hierarchy For example If during cooking the oven experiences an F1 and F2 Fault t
14. adjustments have been made NOTE Hi temperature grease must be present between the Torsion Spring and the Switch Bracket Assembly Item 58 Grease as required to ensure smooth action THE COOK DOOR 35 2 AN LATCH TOGGLE LATCH TOGGLE IS ANGLED IS LEVEL COUNTER CLOCKWISE o IN FIGURE 24 Mis adjusted Cook Door FIGURE 25 Mis adjusted Cook Door APPLY HI TEMP GREASE PRIMARY AND SECONDARY INTERLOCK SWITCHES TO AREA ss G AND PARTS 5 4 Figure 26 5 53 NGC 1076 Actuator Door 54 102684 Screw 8 32 x 1 2 100 CSK 55 102921 Screw 8 32 x 3 8 56 101557 Screw 4 40 x 1 1 4 57 102012 Interlock Switches 58 NGC 1075 Assy Door Switch See Figure 27 for Assy Detail ex ae LATCH TOGGLE TO BE LEVEL OR NEARLY LEVEL SWITCH GAP 0 02 FIGURE 26 Primary and Secondary Interlock Adjustment and Parts 36 THE COOK DOOR FIGURE 27 Door Switch Assembly and Parts DOOR SWITCH ASSEMBLY AND PARTS Figure 27 59 NGC 1072 60 102012 61 NGC 1087 62 NGC 1073 63 101119 64 100059 65 101557 66 102921 67 NGC 1126 68 100639 79 101296 Bracket Latch Switch Micro 0 1A 125VAC Spring Door La
15. 11 To disable the Time State 1 Simultaneously press the Back Arrow and Enter Keys 2 Enter the Access Pin 8 4 6 3 T I M E and Enter 3 When prompted press 9 to re enable or any other Key to disable the Time State FIGURE II Time State PASSWORDS Edit Mode 1 Press Up and Down Arrow Keys simultaneously 2 Enter the Pin 9 and press Enter Test Mode 1 Press Back and Enter Keys simultaneously 2 Enter the Pin 9 4 2 8 amp press Enter Reset Control Soft Restart 1 Press Back and Enter Keys simultaneously 2 Enter the Pin 9 4 7 1 amp Enter Erase 1 Press Back and Enter Keys simultaneously 2 Enter the Pin 3 7 2 7 amp press Enter 3 When asked Erase Menu press 3 WARNING The Erase command permanently deletes all stored Recipes and settings FIGURE 12 Control System Panel Enclosure and Parts CONTROL SYSTEM PANEL PARTS Figure 12 NGC 1040 102960 100505 101954 100193 100184 Ta 3 Cover Keypad Display Nut 4 40 Stainless Reserved For Future Use Display Spacer 1 2 Lg Al 2 Pin Power Cable 26 Pin Ribbon Cable THE CONTROL SYSTEM 8 NGC 1110 Keypad NGC 100506 Connector 10 100182 Cable Connection Optional Feature Assembly Notes
16. 143 100518 Fan 1 Cooling 144 102086 OT2 Cooling Fan 145 101271 K1 Filament Relay 146 101271 K2 Anode Relay 147 101271 K3 Monitor Relay 148 101284 K4 K5 SSR Heater IR Relay 149 102075 OT1 Thermostat Heater 150 100661 Heater Convection 151 100649 Heater IR Element 152 101272 K6 Voltage Relay 153 101206 PS Power Supply 24VDC 154 100861 M1 Magnetron 155 100861 M2 Magnetron 156 102101 T1 High Voltage Transformer 157 102101 T2 High Voltage Transformer 158 102102 FT1 Filament Transformer 159 102102 FT2 Filament Transformer 1 0 Control Board Item Identification and Test Point Location 178 J2 40 Pin Connector for LV Harness 179 J3 3 Pin Connector for VFD Display 180 14 14 Pin Connector for Keypad 181 J5 26 Pin Connector for Display Data 182 16 RS 232 Connector Unused 183 RJ11 Connector for Smart Card Cable SERVICE PARTS AND ILLUSTRATIONS 65 160 100201 161 100201 162 100481 163 100481 164 100083 165 100443 166 100882 C1 High Voltage Capacitor C2 High Voltage Capacitor D1 High Voltage Diode D2 High Voltage Diode Fan 2 Mag Fan Controller Motor Motor Convection Low Voltage Components 167 102012 168 102012 169 102012 170 NGC 1008 171 100505 172 NGC 1110 173 102070 Primary Interlock Secondary Interlock Monitor Safety I O Control Board Display VFD Keypad NGC Oven Mag Thermo Switches Wire Harness Replacement P
17. Display Data RS 232 Connector Unused Connector for Smart Card Cable EPROM Socket Magnetron Current Transformer Voltage Reference 0 5 VDC Voltage Reference Adjustment Blower Controller Pin Configuration Capacitor Beeper Beeper Volume Adjustment 50 SCHEMATIC AND SCHEMATIC PARTS 00000000000000000000 RBI 191 84 5 00000000000000 0000 00 178 i 179 J3 ee r 187 R42 9 Q SKPI P3 o FIGURE 36 I O Control Board and Test Point Locations FIGURE 4 NGC TORNADO CONTROL SYSTEM Chapter 4 The Control System Page 11 SERVICE PARTS AND ILLUSTRATIONS 24 VDC K5 K4 KI K2 K3 K6 MECH MECH MECH MECH rs
18. IR Relay 149 102075 OT1 Thermostat Heater 150 100661 Heater Convection 151 100649 Heater IR Element 152 101272 K6 Voltage Relay 153 101206 PS Power Supply 24VDC 154 100861 M1 Magnetron 155 100861 M2 Magnetron 156 157 158 159 160 161 162 163 164 165 166 102101 102101 102102 102102 100201 100201 100481 100481 100083 100443 100882 SCHEMATIC AND SCHEMATIC PARTS 49 T1 High Voltage Transformer T2 High Voltage Transformer FT1 Filament Transformer FT2 Filament Transformer C1 High Voltage Capacitor C2 High Voltage Capacitor D1 High Voltage Diode D2 High Voltage Diode Fan 2 Mag Fan Controller Motor Motor Convection Low Voltage Components 167 168 169 170 NGC 1008 171 172 NGC 1110 173 102012 102012 102012 100505 102070 Primary Interlock Secondary Interlock Monitor Safety I O Control Board Display VFD Keypad NGC Oven Mag Thermo Switches Wire Harness Replacement P Ns 174 175 176 177 100188 100185 100187 100186 Line Voltage Harness Low Voltage Harness Power Cord Magnetron Wire 1 0 CONTROL BOARD ITEM IDENTIFICATION AND TEST POINT LOCATION Figure 36 178 2 179 5 180 J 181 5 182 16 183 11 184 U15 185 T1 186 P1 187 R42 188 P3 189 C9 190 SKP1 191 R51 40 Pin Connector for LV Harness 3 Pin Connector for VFD Display 14 Pin Connector for Keypad 26 Pin Connector for
19. Ns 174 100188 175 100185 176 100187 177 100186 184 U15 185 TI 186 P1 187 R42 188 P3 189 C9 190 SKP1 191 R51 Line Voltage Harness Low Voltage Harness Power Cord Magnetron Wire EPROM Socket Magnetron Current Transformer Voltage Reference 0 5 VDC Voltage Reference Adjustment Blower Controller Pin Configuration Capacitor Beeper Beeper Volume Adjustment 66 SERVICE PARTS AND ILLUSTRATIONS FIGURE 37 COVERS AND MISCELLANEOUS PARTS Covers and Miscellaneous Parts 192 NGC 1147 Assy Rear Chassis Door 193 NGC 1069 1 Cover Left Side NGC Oven 194 NGC 1069 2 Cover Right Side NGC Oven 195 NGC 1068 Cover NGC Oven 196 102748 Screw 8 32 x 38 Lg TORX HD Security 197 101688 Screw 8 Serrated Phillips TRHD CRES 198 102921 Screw 8 32 x 3 8 PPHD SEM Int Tooth SS 199 NGC 1071 Cover Bottom Front 200 100781 201 10191 202 NGC 1054 1 203 NGC 1064 204 NGC 1176 205 NGC 1177 206 NGC 1148 207 102962 208 NGC 1187 Leg 4 Hole Plug 1 2 Dia Black Assy Keypad Display HSNG Rack NGC Oven Label Schematic Label Service Assistance Label Caution Hot Nut KEPS HEX 48 32 Ext Tooth CRES Pad Abrasive Non slip
20. RELAY RELAY RELAY RELAY oe 101271 101271 101271 101272 0254 24VDC 24VDC 24VDC 24VDC 3 0 40 30 40 L 24 VDC z4vpc V E POWER SUPPLY 24 VDC MONITOR SWITCH g 101206 y a 2Y NO 102012 MONITOR INTERLOCK COMMON 24 VDC BMSC 100443 CONVECTION HEATER COMMAND 2 200 240 SPD 0 10V 1 IR ELEMENT COMMAND VACIN cmp 0COM 2 ENABLE 3 1 0 4 1 0 PRIMARY SWITCH 2 3 PHASE STATUE OK 5 INTERLOCK NCo 3 QUT 0 6 CONTROL NO 102012 4 o SECONDARY SWITCH BOARD SECONDARY SWITCH i NGC 1008 INTERLOCK E NO 102012 VOLT VOLTAGE INPUT COMMON COMMON 100783 m nls AC IR THERMOCUOPLE CCO EE VDF ru a DISPLAY AC a 100505 THERMOCUOPLE CC Lg ar Ra AQ ss CC THERMOCUOPLE CC pase T TEE 14 TEE 14 14 KEYPAD NGC I110 52 SERVICE PARTS AND ILLUSTRATIONS FIGURE 12 CONTROL SYSTEM PANEL ENCLOSURE AND PARTS Chapter 4 The Control System Page 17 Control System Panel Parts 1 1040 Cover Keypad display 2 102960 Nut 4 40 Stainless 3 Reserved For Future Use 4 100505 Display 5 101954 Spacer 1 2 Lg Al 6 100193 2 Pin Power Cable 7 100184 8 NGC 1110 9 100506 10 100182 Optional Feature 26 Pin Ribbon Cable Keypad NGC Connector Cable Connection SERVICE PARTS A
21. SETUP AND INITIAL OPERATION Setup Once oven is properly positioned on the counter remove any packing material and or any foreign objects from within the cavity Install the oven rack by sliding the rack onto the support shelves Programming The oven comes preprogrammed and is ready to operate out of the box Initial Power up To turn the oven On press the Key next to the word on the display The oven will begin to warm up to its predefined cooking temperature of 500 F This takes approximately 10 minutes When the Warm up Cycle is completed the oven will beep and display the Ready State At this point the oven is ready to cook DAILY MAINTENANCE FOR THE NGC The Daily Cleaning Recommendation below will help in maintaining the NGC Tornado oven Be sure to use only TurboChef Oven Cleaner The use of any other cleaning products can damage critical parts and may void warranty on those parts Supplies and Equipment TurboChef Oven Cleaner nylon green scrub pad cleaning towel Step I Prepare the Oven Turn oven off by pressing the Back key The oven will display Oven Off Cooling Down DO NOT attempt to clean oven during the cool down cycle indicated by Cooling Down signal on display a Cooling takes approximately 90 minutes NOTE The oven operates at 500 F and may cause injury if not allowed to cool properly Step 2 Remove the Lower Access Panel n Wi
22. and pull the IR Element from the oven 48 IR ELEMENT AND CATALYTIC CONVERTER Removing and Installing the Catalytic Converter 1 Remove the IR Element 2 Once the IR Element has been removed remove the Catalytic Converter Clip Item135 to access the Catalytic Converter Figure 34 NOTE It may be necessary to remove the Blower Motor Assembly see page 41 to get access to the top of the Catalytic Converter This will allow the Catalytic Converter to be pushed down out of the housing Figure 34 3 Remove the Catalytic Converter Item 136 4 Install a new Catalytic Converter Installing a new IR Element 1 Gently squeeze the new IR Element together in order to get the Terminals and Lead Wires into the cavity and through the mounting holes CAUTION Do not allow the Thermocouple Lead Wires to kink They are solid wire and will break FIGURE 34 IR Element and Catalytic Converter Assembly 2 Once the IR Element is installed expand the IR Element in order to reinstall the Shim Washers Item 131 and Snap Rings Item130 Figure 34 NOTE Be sure that the Snap Rings sit in the grooves on IR Element 3 Reconnect the IR Element Lead Wires to the EMI Filter and the High Limit Thermostat 4 Reconnect the IR Thermocouple Lead Wires to the Thermocouple Extension Wires Yellow to Yellow and Red to Red IR ELEMENT AND CATALYTIC CONVER
23. repaired by anyone except a factory authorized service technician GROUNDING INSTRUCTIONS This 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 appliance is equipped with a cord that has a grounding wire with a grounding plug The plug 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 DO NOT use an extension cord If the power supply cord is too short have a qualified electrician or serviceman install an outlet near the appliance Power Supply Cord Replacement If the power supply cord is damaged it must be replaced by the manufacturer its service agent or a similarly qualified person in order to avoid a hazard WARNING Improper grounding can result in a risk of electric shock RF INTERFACE CONSIDERATIONS The NGC Tornado 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 require ments of Council Directive 89 336 EEC on the approximation of the laws of the Member States relating to electromagnetic compatibility at the time of manufacture However some equipment with sensitivity to
24. required to lift it Lifting and Placement of the Oven Position one or more persons on either side of the oven and lift from the bottom Never lift the oven from the front and rear Place the oven on a coun tertop surface at least 28 inches deep and capable of supporting 200 lbs Once properly positioned on the counter plug the oven into a NEMA 6 30R wall mounted electrical receptacle See Electrical Specifications Restraint Oven Kit P N TC3 0240 An optional system intended to hinder the oven from moving forward during use and or cleaning The Restraint Oven Kit will not prevent the oven from falling off a countertop if the legs are allowed to slide off the edge or if the oven is intentionally or forcefully pulled off Proper installation instructions are included in the Restraint Oven Kit if the operator has ordered one If additional help is needed please call customer service at 800 90TURBO ELECTRICAL SPECIFICATIONS Operating Voltage 208 VAC 240VAC Current Draw 30 Amps Phase 1 Phase Frequency 60 Hz Max Input 5990 6675 watts Microwave Input Power 3500 watts Maximum Independent Input Power WARNING Never lift the oven by its door handle Physical damage to the oven and or personal injury may result The operator must ensure that the oven is properly placed on the 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
25. same procedure measure the leakage with the Cook Door opened to the point just before the Primary Secondary Switches disengage Record the highest leakage THE MICROWAVE SYSTEM FIGURE 21 High Voltage Diode P N 100481 To hold the Cook Door open for this test back out the top center screw around the perimeter of the Cook Door Continue backing this screw out until the Primary and Secondary Interlock Switches disengage As this point tighten the screw until both Switches re engage 7 Using the same procedure measure the leakage around the oven s entire exterior surface Record the highest leakage HOW TO TEST MICROWAVE COMPONENTS Testing the High Voltage Diode P N 100481 The High Voltage Diode Figure 21 is assembly constructed by connecting several 1000 volt 1500 volt semiconductor diodes in a series in order 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 When the High Voltage Winding starts to go toward negative the High Voltage Diode FILAMENT AND HIGH VOLTAGE TERMINALS aa FIGURE 22 Magnetron P N 100861 becomes non conduct
26. signals below these limits may experience interference If your equipment experiences interference the following steps should be considered Increase the physical separation between this oven and the sensitive equipment If the sensitive device can be grounded do so following accepted grounding practices If battery powered microphones are being affected insure that the batteries are fully charged Keep sensitive equipment on separate electrical circuits if possible DO NOT route intercom wires microphone wires or speaker cables near the oven SAVE THESE INSTRUCTIONS FIGURE I NGC Tornado Dimensions SPECS AND DIMENSIONS Dimensions EXTERIOR COOK CAVITY Height 23 with 4 legs 8 Width 26 15 5 Depth 25 7 14 7 28 2 with handle Weight 190 lbs WALL CLEARANCE Back 0 Sides 2 ENTRY CLEARANCE minimum Crated 30 Uncrated 24 Construction EXTERIOR 430 stainless steel front top and sides 4 chrome plated adjustable legs Nickel plated handle Cool to the touch pull down door o E INTERIOR 304 stainless steel line Fully insulated cooking chamber Removable wire cooking rack with optional platter Adjustable lower cooking element INSTALLATION SPECIFICATIONS AND MAINTENANCE Standard Features Recirculating airpath with TurboChef Technologies patented catalytic converter system Multi speed convection blower Conventional wire baking r
27. the oven is in the Test and DIAG Mode Refer to Figures 5 and 6 If a Status Indicator is highlighted backlit the item or component is in an un energized or Off State Conversely if a Status Indicator is not highlighted the component is energized or in the On State PROGRAMMING Edit Mode The Edit Mode enables the operator to alter Recipes and the Cook Chamber Temperature TCC To access the Edit Mode 1 Press the Up and Down Arrow Keys on the Keypad simultaneously 2 When prompted enter the Access Code 9 and then press Enter Changing the Cook Chamber Temperature The first screen in Edit Mode allows you to change the Cook Chamber Temperature TCC by pressing the Up and Down Arrow Keys The operator may adjust the temperature between 450 540 F in 10 F increments Once you have selected the desired temperature press the Enter Key to set TCC Altering a Recipe The NGC Tornado oven control has 128 unique Recipes available for the operator The display shows two 2 pages each with eight 8 Recipe Groups Each Recipe Group contains eight 8 Subgroups or Recipes See Figures 7 and 8 To alter a Recipe 1 Enter the Edit Mode as described earlier 2 Enter the Access Code 9 and set TCC The screen displays the first set of eight 8 Recipe Groups To access the second set of eight 8 Recipe Groups press either the Up or Down Arrow Key THE CONTROL SYSTEM EDIT GRO
28. 102 Filament Transformer 22 23 100599 Fuse 20 Amp 24 102070 Mag 2 Thermostat 25 100861 Magnetron 2 26 NGC 1106 Wave Guide 2 27 102070 Mag 1 Thermostat 28 100861 Magnetron 1 29 NGC 1044 Wave Guide 1 54 SERVICE PARTS AND ILLUSTRATIONS FIGURE 16 MICROWAVE SYSTEM PARTS Chapter 5 The Microwave System Page 23 Microwave System Parts 30 100861 Magnetron 31 102070 Mag Thermostat 32 NGC 1163 Ad Insulator 33 100186 Screw 6 Sheet Metal 34 100186 Magnetron Wire FILAMENT AND HIGH VOLTAGE TERMINALS COOLING FANS 2 FIGURE 17 WAVE GUIDE COVER WAVE GUIDE REMOVAL AND REPLACEMENT Chapter 5 The Microwave System Page 25 Wave Guide Wave Guide Cover Parts 35 NGC 1097 Assy Wave Guide Cover 36 102921 Screws 48 32 x 3 8 SS 37 101688 Screws 48 x 1 2 Sheet Metal PTH 38 NGC 1047 Support Frame 39 102809 40 NGC 1106 41 100861 42 100861 43 NGC 1044 Screws 48 32 x 3 8 CSK 1009 Assy Wave Guide 2 Magnetron 2 Magnetron 1 Assy Wave Guide 1 SERVICE PARTS AND ILLUSTRATIONS 55 FIGURE 18 amp 19 HIGH VOLTAGE TRANSFORMER AND FILAMENT WIRING Chapter 5 The Microwave System Page 26 FT2 Blue AG gt 2 208V Brown TOP VIEW zaov 2 Y Ora
29. 3 2 6 7 9 5 e 9 o o o o o o SHUNT CAVITY PLATE Tightening Sequence FIGURE 30 Cook Door Assembly Tightening Specs Critical Adjustment Notes Figure 29 Item 76 should be oriented with the Gasket Seam at them bottom of the door assembly Gasket should be straight with no twists or pinching Attach insulation to the inside of the door cover using aluminum tape Item 94 DO NOT block openings at bottom Item 89 insulation not shown for clarity Door should be flat without twisting or warpage after tightening all hardware Refer to the chart to the right for torque specs and tightening sequence Attach Item 95 with adhesive backing using the two 2 locating holes on the front cover Item 80 and 77 must mount securely If Item 80 can move after installation reject THE COOK DOOR 14 8 I 4 5 15 Hs 49 10 L Je 7 7 3 2 6 16 SHUNT ASSY DOOR COVER Tightening Sequence SCREW TORQUE CHART Refer to Figure 30 above PART TORQUE PART NUMBER VALUE 85 Bolt 1 4 20 x 1 00 80 In Lbs P N 102945 91 Nut Keps 8 32 21 In Lbs P N 102962 92 Screw 8 32 x 3 8 21 In Lbs Trox Security P N 102748 93 Screw 8 x 1 2 PTH 21 In Lbs P N 101688 40 COOK DOOR INTERLOCKS TROUB
30. 61 Hinge Block 47 102804 Right Hinge only 48 102805 Left Hinge 49 101381 10 32 x 1 2 Hex 55 50 102140 10 Flat 51 102350 10 Split Loc 52 101191 Cap Hole 34 THE COOK DOOR ADJUSTING THE COOK DOOR 1 5 Slightly loosen the two 2 hex head screws the left and right side of the Door Cover See Figure 24 Note 4 Close the Cook Door and press the door squarely against the Oven Flange Starting on left side of the Cook Door tighten the two 2 hex head screws Gently open the Cook Door Tighten the two 2 remaining hex head screws on the right side Repeat the above procedure until the Cook Door sits properly Critical Adjustment Notes 1 The door Figure 24 is adjusted incorrectly Note that the bottom of the Cook Door is rotated away from the Flange CORRECTIVE ACTION Loosen the hex screws and push the bottom of the Door towards the Flange and re tighten The door in Figure 25 is adjusted incorrectly Note the top of the Cook Door is rotated too far away from the Flange and the Latch Toggle is rotated too far counter clockwise The Latch Toggle should be level when the Door is adjusted correctly as in Figure 24 CORRECTIVE ACTION Loosen torx screws and push top of the Door towards the Flange Re tighten screws The bottom of the Latch Toggle will be level when the Door is adjusted correctly See Figure 25 When the
31. A is highlighted backlit in Test Mode 1 A is highlighted backlit Verify 208 240 VAC is going to the Motor Controller via Pins 2 and 3 208 240 VAC is not present Correct Line Voltage Wiring going to Motor Controller 208 240 VAC is present Verify the control wiring from Motor Controller and I O Control Board specifically Low Voltage Wire OR 9 If all wires are OK refer to Motor Controller Trouble Shooting below Motor Controller Trouble Shooting Verify Motor spins freely 1 Motor seized Replace Motor or correct obstruction 2 Motor spins freely Verify Motor Windings a Verify Motor Windings are OK Measure the resistance between windings and chassis Replace Motor if resistances do not in agree with the values in the Motor Winding Resistance table below If Motor is OK Replace Motor Controller 2 A is not highlighted Check Motor per above steps If Motor is OK replace the Controller MOTOR WINDING RESISTANCES TABLE TO FROM DESCRIPTION EXPECTED RESISTANCE Black Red Winding A B 2 0 2 6 Ohms Black White Winding A C 2 0 2 6 Ohms Red White Winding B C 2 0 2 6 Ohms Black White Green Windings to Chassis Open or Red 45 The IR Element and Catalytic Converter provide two very different but essential functions The IR Element provides the bottom browning similar to a residual broiler or salamander type cooking appliance requi
32. CROWAVE SYSTEM COMPONENTS Below is a description of each component within the Microwave Circuit and how these components act within the Circuit Magnetron P N 100861 Magnetrons supply the RF energy at 2 45 GHz and begin to oscillate when they are supplied with approximately 4 1KVDC at approximately 350 mA During operation each Magnetron will output a nominal 1 kW of power THE MICROWAVE SYSTEM 23 FILAMENT AND HIGH VOLTAGE TERMINALS COOLING FANS FIGURE 16 Microwave System Parts High Voltage Transformers P N 102101 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 Circuits They are controlled via the K2 Relay WARNING Never attempt to measure AN the voltage values of the High Voltage Transformers with the High Voltage Transformers enabled Lethal voltage will be present on your meters Reference page 26 Filament Transformers P N 102102 For better operation and reliability the oven uses separate transformers in order to preheat the Magnetron Filament 24 THE MICROWAVE SYSTEM Prior to fully energizing the Microwave Circuits the Control energizes the Filament Transformers for approximately three 3 seconds prior to supplyi
33. Cook Door is adjusted correctly the Door will snap shut Door mount hardware See page 33 Figure 23 Items 49 52 WARNING Check for excessive Microwave Leakage after adjusting the Cook Door See page 27 for proper procedure ADJUSTING THE PRIMARY AND SECONDARY INTERLOCK SWITCHES The Primary and Secondary Interlock Switches are located on the left side of the oven To properly adjust the switches follow the procedure below l 8 Ensure the Cook Door is adjusted Refer to the previous section on adjusting the Cook Door Open and close the Door several times to ensure the Cook Door closes smoothly and the Door Actuator Item 53 clears the slot in the Flange Reference Figure 26 While the Cook Door is closed verify that the bottom of the Toggle is level or very nearly level to the bottom of the frame If not readjust the Cook Door While the oven is cool temporarily adjust the Primary and Secondary Interlock Switches by loosening the 8 32 screw Item 55 and the two 2 4 40 screws Item 56 Figure 26 Rotate the Interlock Switches Item 57 until the gap between the Switch Paddles and the Switch Body is 0 02 inch Figure 26 Restore power to the oven Allow the oven to Warm up to its Set Temperature Allow the oven to remain at the Set Temperature for ten 10 minutes after warm up before making any final adjustment Securely tighten Items 55 and 56 once any final
34. EAKAGE FOR MICROWAVE SAFETY An RF Microwave leakage test must be performed at the conclusion of the following service tasks a Door removal replacement and or adjustment Wave Guide removal and or replacement Magnetron removal and or replacement oven must taken out of service immediately until the defect is corrected In addition the CDRH Regulations 21 Subpart C 1002 20 requires that WARNING If the unit fails the radiation test leakage greater than 4 mW cm2 the leakage readings of over 4 mW cm2 must be reported to the manufacturer Procedure for Measuring RF Leakage 1 Place the oven in Warm up Mode and allow it to warm up to the Cook Set Temperature TSET This should take no more than 10 minutes 2 Once the oven has warmed up place the oven into Test Mode see page 12 Place a water load into the Cavity Water load must conform to the following specification a Volume 275ml 15ml b Temperature 68 9 F c Vessel Low form 600 ml beaker with an inside diameter of approximately 3 35 and made of Pyrex or glass ceramic 3 Position the Microwave Survey Meter as shown in Figure 20 4 Press and hold the MGTRON Soft Key to energize the Microwave System 5 While holding the Soft Key move the Survey Meter around the outline of the Cook Door keeping the tip of the Meter in contact with and perpendicular to the Cook Door Record the highest leakage 6 Using the
35. EM p al zl BL 500 SPD CMD FILTER UE Bg 1 0 4 L2 2 1 200 240 5 8 El corcom 40VSK 3 VAC IN 10 6 FI I2 AMPS CLASS CC F2 12 AMPS CLASS CC FIGURE 35 NGC Tornado Schematic P N NGC 1070 Revision H July 22 2004 F3 20 AMPS CLASS CC FIGURE 35 NGC OVEN SCHEMATIC P N NGC 1070 See inside of this fold out page Rev 2 Board VFD Display Single Phase 280 240 VAC 60 Hz Notes Schematic shows the oven with door open and without power applied Color Code Line Voltage BL Blue Line V 208 240 BR Brown Line V 208 240 OR 240 Line Input for Tap 3 on all Transformers BK Hi Temp 240 VAC Wire Color Code Low Control Voltage BK Black 24 VDC Common OR Orange Status Input WH White Control Input RD Red 240VDC Color Code High Voltage Tension WH Hi Voltage Wire For Mag 1 BK Hi Voltage Wire For Mag 2 SCHEMATIC PARTS Figure 35 See the inside of fold out page Line Voltage Components 137 100543 EMI Filter 138 100586 F1 F2 and F3 Fuse Holders 139 100592 F1 12 Amp Fuse 140 100592 F2 12 Amp Fuse 141 100599 F3 20 Amp Fuse 142 100783 Voltage Module 143 100518 Fan 1 Cooling 144 102086 OT2 Cooling Fan 145 101271 K1 Filament Relay 146 101271 K2 Anode Relay 147 101271 K3 Monitor Relay 148 101284 K4 K5 SSR Heater
36. F BLISO 8 08 8 N dL i 9 or 9 zye ad a 4 2 BR280 10 080 pes K2ANODE M2CD MICD Jowo 5310 3 J E 12 4 1 5 13 is po 14 an nee 819 o M2F MIF 15 84 97 6 55 16 RD 16 M2FA 17 BK 23 8 8 4 3 3 das as gt 2 paves 19 RD 19 lt 3 20 BK 20 m FA F 9 FA 08275 21 21 5 SS MAG TAPS 22 BK 22 sie FAN 1 2 208VAC 23 BK 23 5 KI FILAMENT 55 2 A 1 1 3 240VAC 24 24 MAG MAG 2 o 25 RD 25 ac3 BLI20 o 4 BL 160 26 RD 19 PINI PINI 3 27 WT 27 C wa 27 PIN2 PIN2 BR230 9 ac4 28 WT 28 o 6 2 BR290 29 255 Pms Pins 30 WH 30 n wk 3011 29 PING RELAY ASSY 3I WH 31 WE ving a A B MANUAL RESET PINOUT 32 BK 32 el pine ENC HX ELEMENT 327 31 33 BK 33 lt 3300 5 34 08540 gt 13 1 OHMS 2 35 Cwn28 P N 100661 HT520 36 301 BL 510 C 37 42 BL 140 2 RD 19 2 1 a AO 8 z z s BR 250 la BOTTOM IR 40 50 266 ELI 072 BRZI0 EE 44 OHMS BR220 er No Bil j K5 P N 100649 kr MZ RED eese Ur AE B2 A2 s M3 WHITE a PHASE F2 F3 E our VOLTAGE MODULE ___ pRooo Bl Al GREEN 4 BMSC 9 BLOOO e s me
37. HEMD SW RTN KI FILAMENT ONT 0407 OUY HE a 240vat susc COMM 2 Le Ju 2 XI B MAG FIL QUT A KS BOTTOM IR OUT 8 sus 404 6 8 VOLTS MoD OUT CONV OUT Y RELAY ASSY BMSC 3 ENABLE QUT 8 PINOUT BMSC 4 COm RTN T WX ELEMENT 24V VOLT MODULE 3 2 B _ 57 THERMOCOUPLES lt EC CM BOTTOM IR E jp Sooo WATTS n i pz a n sue 02 uns cass 3 20 MPs 183 83 184 15 KE 000000000000000020 J4 96000000000090002020 178 J2 gt 8 Af A 513 0902000000000 0000000000000 79 19 3 Sood 190 a SKPI Schematic Parts Line Voltage Components 137 100543 EMI Filter 138 100586 F1 F2 and F3 Fuse Holders 139 100592 F1 12 Amp Fuse 140 100592 F2 12 Amp Fuse 141 100599 F3 20 Amp Fuse 142 100783 Voltage Module
38. I O Control Board F7 Thermocouple Open CC Thermocouple Reads 999 F or IR Thermocouple Reads 1999 F 1 Check the connection of Open Thermocouple on the I O Control Board If the Connection is OK verify Thermocouple is not an open circuit by using your Ohm meter The Cook Chamber Thermocouple should measure approximately 4 5 Ohms and the IR Thermocouple should measure around 30 40 Ohms Measurement to be made at the I O Control Board 40 Pin Connector a Thermocouple indicates open circuit Replace defective Thermocouple Thermocouple OK Replace the I O Control Board THE CONTROL SYSTEM ISSUE RESOLUTION Cook Door Open Message when door is closed 1 Determine which Interlock Switch is open by entering the Test Mode Examine the Switch es indicated as Open If the Switch es is are mechanically opened i e the Cook Door is not actuating the switch then refer to page 34 to adjust the Cook Door If the switches are mechanically closed but the Control indicates an Oper verify wiring going to each Interlock Switch Correct any wiring issue or replace the Interlock Switch if it is failed closed F1 Blower Running Status Bad Motor not running when commanded 2 Status Indicator A is not highlighted in Test Mode Status Indicator A is highlighted backlit in Test Mode Verify 208 240 VAC is going to the Motor Controller via Pins 2 and 3 208 240
39. LE SHOOTING ISSUE RESOLUTION Cook Door Open Message Determine which Interlock Switch is Open Access Test Mode to view Interlock Switch status 1 Primary and or Secondary Interlock s are is open Verify action of the Latch Assembly and Cook Door When door closes Actuator should freely clear the slot on the Flange and when it strikes the Toggle Latch should rotate smoothly to its closed position Actuator doesnt clear slot Bend or adjust actuator If the Actuator is worn or has yielded replace the Actuator a Toggle doesn t rotate freely or smoothly Replace any worn parts Clean assembly and re lubricate all rotating parts Be sure to grease the Torsion Spring See Figure 26 and 27 a Actuator and Toggle OK Check adjustment and wiring on the Interlocks If adjustment is necessary see page 34 for the proper adjustment procedure 2 P Monitor Switch is open Verify that Door closes freely and completely a Door does not close freely Remove obstructions or readjust the Cook Door per the instructions on page 34 a Door closes properly Readjust the Monitor Safety Switch per the instructions on pages 36 37 The Convection Circuit provides the high temperature airflow necessary to brown and cook food items CONVECTION SYSTEM COMPONENTS The following is a description of each component within the Convection Circuit and how each acts within the Circuit Figure 31 below shows a bloc
40. Limit Thermostat is not tripped a If High Limit is tripped Reset and allow the oven to warm up u If High Limit is not tripped Follow the instructions below High Limit is not tripped Place a small water load in a microwave transparent container approx 275 ml in the oven and place the oven in Test Mode Press the MGTRON Key to actuate the microwave While holding down the MGTRON Key watch the CC and IR Temperatures If either tem perature bounces substantially there may be a noise EMI problem To correct this problem examine the wire routing for each Thermocouple wire If the wires are routed near any high voltage components such as the Magnetron or High Voltage Transformers re route the wires If this does not correct the problem verify that both Magnetrons are securely mounted Call Customer Service for further details at 800 90TURBO The Microwave System is the most complex system in the oven Proper care must be taken during servicing to protect both the operator and technician OVERVIEW OF A MICROWAVE CIRCUIT The Microwave Circuit consists of a Magnetron and Voltage Doubler Circuit The Voltage Doubler consists of a special step up transformer a capacitor and a diode MONITOR CIRCUIT DESCRIPTION In addition to understanding the High Voltage Circuit it is imperative to understand how the Monitor Circuit operates The Monitor Circuit is a failsafe circuit designed to protect the operator if both the Primary a
41. MODE The Test Mode allows the service technician to operate the oven s subsystems individually It also allows the operator to configure various presets To enter the Test Mode 1 Press the Back Key until the display is in the Off State 2 Press the Back and Enter Key simultaneously 3 Enter the access code 9 4 2 8 when prompted and press Enter The Test Screen displays the Software Version Cook Chamber and IR Element Temperature at the top of the screen The Control also displays the THE CONTROL SYSTEM TEST NGC BLOWER HEATER FAULTS MGTRON STEST IR ELE PIN AEN Mn TEST NGC VAKKK CC 81 F IR 500 F CC 81 F 00 iw IR SI FIGURE 5 Test Mode Screen 1 first of two 2 pages of the test function options Figure 5 To display the second page Figure 6 press either the Down or Up Arrow Key To test a component or sub system press the corresponding Soft Key TEST FUNCTION OPTIONS Blower Speed The Blower Key increments the Blower Speed in 10 steps When the Blower Speed is 100 the next press sets the speed to 0 Electronic Compartment Temperature The ELEC Key displays the temperature inside the electronic enclosure Self Test Function The STEST Key initiates the Self Test function to test all major components of the oven To run the Self Test press the corresponding Soft Key once Press the Back
42. ND ILLUSTRATIONS FIGURE 13 MONITOR CIRCUIT SHOWN IN FAILSAFE STATE Chapter 5 The Microwave System Page 21 PRIMARY AND SECONDARY K2 HV TI INTERLOCKS CLOSED F3 FUSE RELAY HV TRANSFORMER gt 20 rod e e NC LINE VOLTAGE BLOWN hed otc t CONTROL i 823 ih 24 VDC T2 NC HV TRANSFORMER CONTROL 5 e NO K3 MONITOR iL NO 2 LINE VOLTAGE RELAY L2 i Te 2 1 9 o oT 6 MONITOR SWITCH e 724 VDC al CONTROL NEN EE FIGURE 15 MICROWAVE SYSTEM PARTS Chapter 5 The Microwave System Page 23 Microwave System Parts 11 102101 High Voltage Transformer 2 12 102101 High Voltage Transformer 1 A 13 100201 High Voltage Capacitor 2 14 100201 High Voltage Capacitor 1 15 100481 High Voltage Diode 2 fig 16 100481 High Voltage Diode 1 Se 17 102102 Filament Transformer 2 18 100083 Mag Cooling Fan WS 19 101271 K3 Monitor Relay 20 20 101271 K2 High Voltage Relay 21 101271 Filament Relay EN 22 102
43. SWITCH NGC 1008 INTERLOCK VOLT VOLTAGE INPUT COMMON o COMMON 100783 BB AQ TN IR THERMOCUOPLE XC 71 VDF AQ DISPLAY EC THERMOCUOPLE CC Lat 100505 AC S CC THERMOCUOPLE CC FIGURE 4 NGC Tornado Control System KEYPAD NGG 1110 THE CONTROL SYSTEM CONTROL SYSTEM COMPONENT DESCRIPTIONS 24 VDC Power Supply P N 101206 24 VDC Output at 40 Watts Supplies control voltage for I O Control Board 24 VDC Mechanical Relays and Solid State Relays KI Mechanical Relay P N 101271 240 VAC 30 Amp Double Pole Double Throw 24 VDC Relay Coil Switches power to the Magnetron Filament Transformers K2 Mechanical Relay P N 101271 240 VAC 30 Amp Double Pole Double Throw 24 VDC Relay Coil Switches power to the Magnetron High Voltage Transformers K3 Mechanical Relay P N 101271 240 VAC 30 Amp Double Pole Double Throw 24 VDC Relay Coil Safety Interlock device designed to short L1 and L2 if the Monitor Switch opens before the Primary and Secondary Interlock Switches K4 K5 SSR P N 101284 240 VAC Dual 40 Amp Solid State Relay K4 right controls the Convection Heater and K5 left controls the IR Element K6 Mechanical Relay P N 101272 240 VAC 30 Amp Three Pole Double Throw 24 VDC Relay Coil Responsible for switching between the 208VAC and 240VAC taps on the High Voltage and Filament Transformers Interlock Switches P N 102012 for all three Primary Sec
44. Shunt Plate Cover Door NGC Spacer Shunt Door Shunt Cavity Open Door Hinge Block Spacer Plastic Edge Handle Door Actuator Door Shim Door Latch Bolt 1 4 20 x 1 00 Label Precaution 87 102809 88 NGC 1165 89 NGC 1125 90 NGC 1127 91 102962 92 102748 93 101688 94 102698 95 NGC 1155 96 NGC 1170 SERVICE PARTS AND ILLUSTRATIONS 8 32 x 3 8 CSK 100 Label Caution Empty Kit Door Insulation Channel Door Handle Nut Keps 8 32 Screw 8 32 x 3 8 Trox Security Screw 8 x 1 2 PTH Tape Aluminum Name Plate TurboChef Label Service 59 60 SERVICE PARTS AND ILLUSTRATIONS FIGURE 3I CONVECTION CIRCUIT BLOCK DIAGRAM Chapter 7 Convection Circuit Page 41 BOTTOM IR CONTROL wH 28 MAIN HX CONTROL 30 aimul es t HX ELEMENT 81540 e 22 21 f SSR BL510 pap 100649 12 TUN K5 K4 BOTTOM IR A 3000 WATTS BI 14 4 OHMS OR 9 2 100661 2 8 RD 24 a 25 LI WT 31 BK 32 MI BLK 240 M3 WHITE s UUE E E 4 BMSC SPD CMD Simeon 2 ENABLE 3 1 0 COM 4 BLWR 2 200 240 STATUE OK 5 MTR 3 VAC IN 1 0 COM 6 LI
45. TE If an Event is unused the Air param eter may default and be displayed as 10 Once the desired changes have been made test the Recipe by pressing the Test Soft Key This will execute the altered Recipe Once satisfied with the Recipe press Save to permanently store any changes Press the Back Arrow Key four 4 times to exit the Edit Mode USER CONFIGURABLE OPTIONS Users may enable or disable the Edit Mode Done State and Test State Edit Mode For security purposes the Edit Mode can be disabled To disable the Edit Mode 1 Simultaneously press the Back Arrow and Enter Keys 2 Enter the Access Pin 8 4 3 3 T I D E and Enter 3 When prompted select 9 to re enable the Edit Mode or any other Key to disable the Edit Mode I5 16 THE CONTROL SYSTEM ENTER COOK TIME 00 20 FIGURE Io Done State Done State The Done State Figure 10 can be removed to eliminate the option to Save an altered Time or the option to Cook More To disable the Done State 1 Simultaneously press the Back Arrow and Enter Keys 2 Enter the Access Pin 3 6 6 3 D O N E and Enter 3 When prompted press 9 to re enable or any other Key to disable the Done State Time State This state can be removed in order to prevent the operator from adjusting the Total Cook Time prior to pressing the Start Soft Key to begin a Cook Cycle Figure
46. TER PARTS Figure 34 130 101312 Snap Ring 131 102449 Washer Shim 132 100649 IR Element 133 NGC 1116 Shield Microwave 134 101688 Screw 8 x 1 2 Sht Metal PTH 135 NGC 1030 Clip Catalytic Converter 136 NGC 1012 Catalytic Converter VFD DISPLAY 64 X 128 DOTS CN2 2 25 26 E 25 26 P2 cN3 s 25 26 25 26 a gt MAG 2n PS dt CT K2 B MAG OUT BMSC SEL ASPEN J6 1 9 MONITOR NO INTER IN PRIMARY NO INTER IN SECONDARY NO INTER IN BMSC 9 STATUS OK HX STATUS IN MAG THERMO SW IN VOLT MODUAL IN 24V PS IN 24V PS IN 24V P amp S INTER RTN 24V MONITOR RTN 24V MAG THEMO SW RTN BMSC 0 10V OUT BMSC COMM 2 KI B MAG FIL OUT 5 B BOTTOM IR OUT K6 B VOLTS MOD OUT K4 B CONV OUT BMSC 3 ENABLE OUT BMSC 4 COm RTN 24V VOLT MODULE RTN IR THERMOCOUPLES EC cc J4 12 eoeoouoco orm 4 CO CO IO IO IO IO IO m m P4 5 75 P6 12 J6 12555 KEYPAD
47. UPS GROUPA GROUPE ITEM 1 GROUP B GROUP ITEM 2 ITEM 3 ITEM 4 GROUPA lt GROUP1 ITEM 5 ITEM 1 COUNT 0 COOK TIME 00 00 IR SETPT 500F ITEM 6 TIME AIR WAV 1 KKK 2 3 KKK KKK ITEM7 4 KKK KKK 5 KKK 6 KKK KKK ITEM 8 TEST SAVE FIGURE 7 Edit Groups 3 Select the Recipe Group which contains the individual Recipe you wish to alter Select which Recipe you wish to alter by pressing the Soft Key corresponding to the Recipe Item Figure 8 4 Use the Up and Down Arrows Keys to navigate through a Recipe Use the Keypad and Enter Key to alter any of the following three 3 parameters See Figure 9 1 Cook Time Total duration of the Cook Cycle Enter the desired time and press Enter Valid times are between one 1 second and five 5 minutes 2 Infrared Set Point Temperature IR SETPT The relative temperature which the lower radiant element will maintain during the entire Cook Cycle Valid temperatures are between 500 F and 1150 F 3 Events 1 6 Use the Keypad and Enter Key to enter values for Percent Time Air and Microwave The Time for all Events must total 100 The operating system will not allow a combi nation of Events not totaling 100 or that exceed 100 FIGURE 8 Edit Groups FIGURE 9 Edit Groups The Air and Microwave MW parameters are valid between 10 and 100 NO
48. VAC is present Verify control wiring from the Motor Controller and I O Control Board specifically Low Voltage Wire OR 9 If all wires are OK then refer to page 45 for Motor Controller Trouble Shooting 208 240 VAC is not present Correct wiring going to the Motor Controller Refer to page 45 F1 Blower Defective for Motor Controller Trouble Shooting F3 Magnetron Current Low Check that the K2 Mechanical Relay is in good working order If Relay is OK Refer to page 30 F3 Magnetron Current Low for detailed instructions on trouble shooting F8 Heat Rise Low NOTE This message occurs in Warm up and Self Test if the oven fails to warm up in a prede termined time period Verify the High Limit Thermostat is not tripped u If High Limit is tripped Reset and allow the oven to warm up u If High Limit is not tripped Proceed to instructions below High Limit is not tripped Check both K4 and K5 SSRs by activating them in Test Mode When actuated the control input of the SSR will go to 0 00 VDC When the relay is not actuated the input will read 24 00 VDC If the control voltage is not pulled down during actuation Verify the wiring between SSR and the I O Control Board Replace SSR if wiring OK If the control voltage is pulled down Refer to Figure 31 on page 41 20 THE CONTROL SYSTEM ISSUE RESOLUTION F2 Cook Temperature Low 1 Verify the High
49. a Recipe Each Recipe may have up to six Events depending on programming Each Event lasts a percentage of the Total Cook Time and can be set between 0 and 100 of the Total Cook Time The sum of all the Event Percent Times must equal 100 Total Cook Time The total duration of a Recipe Percentage Time An event subset that specifies the duration of the Event Percentage Air An event subset that specifies the relative amount of impingement airflow speed of convection motor during the Event Valid between 10 and 100 NOTE Maximum 100 7100 RPM Blower Motor Speed Blower Motor Speed scale is linear Percentage Microwave MW An event subset specifying the microwave cycle on time during the Event Valid between 0 and 100 Fault Code A code assigned to an Event that the Control considers to be a failure Upon discovering a Fault the Control will display the Fault Code and a brief description of the failure The Control will also increment the Fault Code Counter Error Message A message that is displayed when an unusual event occurs The Control will display the Error Message only when it occurs Error Messages are not logged in the Fault Code Counter 7 The NGC Tornado oven has the ability to continually monitor and log various fault conditions Some fault conditions will terminate Cook Cycles while others will not Please refer to the Fault Code Table on page 10 for more detailed information When a faul
50. ack Independently controlled bottom browning element Stackable design Smart Voltage Sensor Technology Factory programmed with up to 128 cooking programs Smart Card for remote programming Warranty 1 year parts and labor Accessories Additional Charge 24 stainless steel oven stand with locking casters for single units 17 stainless steel oven stand with locking casters for stacked units Certifications UL cUL NSE FDA FCC c UL us ANSINSF 4 815 Packaging All ovens are packaged in a double wall corrugated box with integrated corrugated skids INSTALLATION SPECIFICATIONS AND MAINTENANCE Power Supply North America SMART VOLTAGE SENSOR TECHNOLOGY Universal Voltage 208 240 VAC 60 Hz 1 phase Amperage Nameplate rating 30 Amp 3 wire including ground Cordset 10 gauge 3 conductor 5 foot cordset Plug NEMA 6 30 NOTE The Smart Voltage Sensor Technology does not compensate for lack of or over voltage situations It is the responsibility of the owner to supply voltage to the unit according to the above specifications DELIVERY AND PRODUCT PLACEMENT Remove oven from carton Immediately note any damage and contact shipping company within 24 hours in order to file a claim TurboChef will not be responsible for product damaged in shipment The carton may be discarded after oven is removed WARNING Oven weight is approx 190 lbs Two or more persons are
51. d Filament Checking a High Voltage Transformer or Filament Transformer High Voltage and Filament Transformer Resistance Table Microwave System Trouble Shooting Chapter 6 The Cook Door Removing Reinstalling the Cook Door Cook Door Parts Adjusting the Cook Door Adjusting the Primary and Secondary Interlock Switches Primary and Secondary Interlock Switches Adjustments and Parts Door Switch Assembly and Parts Adjusting the Monitor Safety Switch Monitor Safety Switch Parts Cook Door Assembly Cook Door Parts Screw Torque Chart Interlocks Trouble Shooting Chapter 7 The Convection Circuit Convection System Components Convection Circuit Parts Blower Motor Parts Convection Circuit Trouble Shooting Motor Winding Resistance Table 21 21 22 22 23 24 25 26 26 27 28 29 30 33 33 34 34 35 36 36 37 38 38 39 40 41 42 43 44 45 Chapter 8 IR Element and Catalytic Converter Components IR Element and Catalyst Removal Removing the IR Element Removing amp Installing the Catalytic Converter Installing a New IR Element IR Element and Catalytic Converter Parts Chapter 9 Schematic and Schematic Parts NGC Tornado Schematic Schematic Parts Line Voltage Components Low Voltage Components Wire Harness Replacement P N s I O Control Board Item Identification and Test Point Locations Chapter 10 Service Parts and Illustrations Figure 4 NGC Tornado Control System Figure 12 Control System Panel Enclos
52. e Cook Chamber Temperature is below 150 F Cool Down A subset of the Off State During Cool Down the oven will circulate the main convection blower until the Cook Chamber Temperature is below 150 F Ready State Refers to an oven that has successfully warmed up to the predefined Set Temperature At this point the oven control is ready to receive cook commands via the Keypad Set Temperature TSET A predefined temperature at which the oven cooks Cook Chamber Temperature TCC The actual temperature registered by the Cook Chamber Thermocouple Edit Mode The mode which enables the user to change stored or predefined Recipes and the Set Temperature Warm Up The mode when the oven is warming itself to the Set Temperature Idle Mode Similar to the Ready State In this mode the oven s control may cycle the blower or heaters in order to maintain the Set Temperature Cook Cycle A period of operation as defined by a Recipe Test Mode A special diagnostic mode that enables the service technician to turn on and off all oven systems independent of one another Keypad The primary interface for the operator Display Displays all visual information to the operator Self Test STEST A special diagnostic function that tests all critical subsystems to determine their operational state Recipe A set of user defined Events that determine a Cook Cycle THEORY OF OPERATION Events A single operational element that is a part of
53. ecessary to gently pry the Wave Guide Covers to remove them from the oven floor as they are sealed with RTV FIGURE 17 Wave Guide Cover Wave Guide Removal and Replacement THE MICROWAVE SYSTEM 5 Clean the oven floor where the new Wave WAVE GUIDE WAVE GUIDE COVER PARTS Guide Cover will sit with Acetone Fi igure 17 35 NGC 1097 6 Apply a 1 8 diameter bead of high temperature 36 102921 RTV P N 102562 along the outside edge of 37 101688 the flanges surrounding the Wave Guide 38 NGC 1047 NOTE It is important to use the correct high 39 102809 temperature RTV as supplied by TurboChef 40 NGC 1106 41 100861 7 Place the new Wave Guide Cover in place 42 100861 Secure with the fourteen 14 8 Sheet Metal 43 NGC 1044 Screws removed in Step 3 Assy Wave Guide Cover Screws 8 32 x 3 8 SS Screws 8 x 1 2 Sheet Metal PTH Support Frame Screws 8 32 x 3 8 CSK 100 Assy Wave Guide 2 Magnetron 2 Magnetron 1 Assy Wave Guide 1 25 THE MICROWAVE SYSTEM TOP VIEW T2 Brown Orange 208V Blue Brown 240V 24 240V Orange Blue 208V 3 TD yp dE M e t SIDE OF OVEN FIGURE 18 High Voltage Transformer Wiring WAVE GUIDE REPLACEMENT AND CLEANING NOTE If the Wave Guide is contaminated with excess debris it is very importan
54. ence Considerations Chapter I Installation Specifications and Maintenance Specs and Dimensions Dimensions Construction Standard Features Accessories Certification Packaging Power Supply North America Delivery and Product Placement Lifting and Placement of the Oven Restraint Oven Kit Electrical Specifications Setup and Initial Operation Setup Programming Initial Power Up Maintenance Chapter 2 Theory of Operation The Theory of Operation Glossary of Common Operating Terms Chapter 3 Fault Codes To View Fault Codes Fault Code Definitions Fault Code Table Chapter 4 The Control System Control System Schematic Control System Component Descriptions Test Function Options Status Indicators Programming User Configurable Options Passwords Control System Panel Parts Control System Trouble Shooting 11 12 13 14 14 15 16 17 18 Chapter 5 The Microwave System Overview of a Microwave Circuit Monitor Circuit Description Microwave Circuit Theory of Operation Microwave System Parts Microwave System Components Wave Guide Cover Replacement Wave Guide Wave Guide Cover Parts Wave Guide Replacement and Cleaning High Voltage Transformer amp Filament Transformer Replacement Wiring the High Voltage Transformers Wiring the Filament Transformers Measuring RF Leakage for Microwave Safety Testing Microwave Components Testing the High Voltage Diode Checking a Diode Checking a Capacitor Checking a Magnetron for Open Share
55. er Access Panel Step 10 Clean Oven Exterior Wipe the oven exterior with a clean damp towel a Oven is ready to turn on DO S AND DO NOT S DO Ensure the oven is cleaned daily Use only TurboChef Oven Cleaner Remove items from the oven as soon as they are cooked Use only microwave safe TurboChef approved cooking accessories in the oven a Review cooking instructions to ensure oven set tings are correct for corresponding products Keep the TurboChef Installation Guide for future reference Call TurboChef immediately if Wave Guide Caps are broken DO NOT m Lift oven by handle Slam or mishandle the oven door m Place foil or metal objects of any kind in the oven Operate the oven without food in the cook chamber x Frequently open and close the door to check the product amp Cook items wrapped in plastic or any type of cling film amp Put products in the oven until ready to cook m Use cleaning agents that are not approved for the oven Allow any cleaning solution or water to remain on the bottom of the cooking chamber after cleaning or at any other time Place excessive weight on top of the oven THE THEORY OF OPERATION The TurboChef NGC Tornado oven utilizes three independent heat transfer mechanisms in order to rapidly cook food The systems are as follows Convection Infrared energy Microwave energy By combining these mechanisms along wit
56. esistance is different then the Table indicates replace the Transformer Wave Guide 1 Replace Wave Guide Covers per Figure 17 on page 25 NOTE Do Not remove the two 2 topmost and two 2 bottommost screws as shown in Figure 17 These screws secure the Wave Guide to the bottom of the oven cavity The proper fit and adjustment of the Cook Door is essential for safe and reliable operation of the NGC Tornado oven The Cook Door provides three primary functions 1 To protect the operator from the hot convection airflow 2 To protect the operator from exposure to microwave energy 3 To actuate the Interlock Switches REMOVING RE INSTALLING THE COOK DOOR To remove or reinstall the Cook Door follow the steps below Refer to Figure 23 Open the Cook Door to its full open position Locate the two 2 thru holes in the bottom of the left and right hinge assemblies Insert a screw or nail into the holes to keep the hinges open while removing the Cook Door FIGURE 23 Cook Door Removal amp Parts THE COOK DOOR 33 2 Locate and remove the two 2 10 32 x 1 2 hex screws on the left and right side of the door NOTE The plastic caps have to be removed 3 Remove the Cook Door by pulling the door away from the oven Door will slide off the hinges COOK DOOR PARTS Figure 23 44 102809 8 32 x 3 8 PFH CSK 45 NGC 1060 Assy Oven Door 46 NGC 10
57. ght 4 Rotate the Monitor Safety Switch Item 71 71 102012 Switch Limit Micro until the gap between the Switch Paddle and 72 NGC 1126 Plate Door switch the Switch Body is 0 02 inch 73 101912 Standoff 8 32F Fx1 in S 74 102921 Screw 8 32 x 3 8 75 102902 Screw 4 40 x 5 8 38 THE COOK DOOR FIGURE 29 Cook Door Assembly COOK DOOR ASSEMBLY See Figure 29 above For mis adjustments see Figures 24 and 25 on page 35 COOK DOOR PARTS Figure 29 and 30 76 NGC 1151 Assy Shunt Plate 77 NGC 1056 Cover Door NGC 78 NGC 1057 Spacer Shunt Door 79 NGC 1059 Shunt Cavity Open Door 80 NGC 1061 Hinge Block 81 NGC 1062 Spacer Plastic Edge 82 102750 Handle Door 83 NGC 1076 002 Actuator Door 84 85 86 87 88 89 90 91 92 99 94 95 96 1132 102945 1138 102809 1165 1125 1127 102962 102748 101688 102698 1155 1170 Shim Door Latch Bolt 1 4 20 x 1 00 Label Precaution 38 32 x 3 8 CSK 100 Label Caution Empty Kit Door Insulation Channel Door Handle Nut Keps 8 32 Screw 48 32 x 3 8 Trox Security Screw 8 x 1 2 PTH Tape Aluminum Name Plate TurboChef Label Service o o o o o o d e 16 8 4 5 8 15 o e I2 19 14 10
58. h the ability to control each mechanism independently the NGC Tornado oven is able to reduce the cook time of most foods by 70 90 percent THEORY OF OPERATION Figure 2 below represents the oven s different systems and the critical components of each system Should a problem arise with any of the components listed below please turn to the appropriate section within this manual for further instructions For the purpose of this manual each independent heat transfer mechanism is individually identified For instance if an oven is experiencing difficulties browning the food focus on the Convection Circuit and or the Infrared Circuit versus the Microwave Circuit Focus on the Microwave System if an oven is browning the food but not heating the food Chapter 4 CONTROL SYSTEM Chapter 5 MICROWAVE SYSTEM I O Control Board Magnetrons Keypad High Voltage Transformers Display Filament Transformers Mechanical Relays SS Relays High Voltage Capacitors High Voltage Diodes Fuse FIGURE 2 NGC Tornado Systems and Critical Components Chapter 7 CONVECTION SYSTEM Chapter 8 BOTTOM IR AND CCV Convection Heater Bottom Infrared Element Mechanical Relays SS Relays Blower Controller Convection Blower Catalytic Converter Hi Limit Thermostat THEORY OF OPERATION GLOSSARY OF COMMON OPERATING TERMS Off State All the oven s control systems are off and th
59. he Microwave System 1 Amp 0 High Voltage Transformer not energizing Check K2 Relay and wiring going to suspect High Voltage Transformer K2 Relay or wiring bad Replace K2 Relay and or repair wiring K2 Relay OK Check High Voltage Transformer See the Table on page 29 for resistance values Replace High Voltage Transformer if defective Amps 3 Amps on High Voltage Transformer Magnetron is not oscillating but High Voltage Transformer is energizing Diodes failed Replace Diodes Diodes OK Replace defective Magnetron Magnetron Circuit is Drawing Excessive Current Measure resistance of High Voltage Capacitor s Resistance should start out in the megohm range and continue to rise as the probes are held on the Capacitor If the resistance is low less than the megohm range replace the Capacitor and visually check the associated High Voltage Transformer Primary winding for signs of over heating winding is very dark and discolored If Transformer Primary Winding looks bad replace it 3l 32 THE MICROWAVE SYSTEM ISSUE RESOLUTION High Voltage and or Filament Transformer s 1 Determine if the High Voltage or Filament Transformer s is defective Use an Ohm meter to measure the Primary and Secondary Winding Covers Broken Faulty Resistances Refer to the High Voltage and Filament Transformer Table on page 29 to determine if the Transformer is OK If the r
60. he oven will only report a F1 Fault since the software will halt all actions upon discovering the F1 Fault F7 and F8 Faults are displayed on the primary screen and are not displayed or counted in the Fault Log NOTE All Fault Codes listed in Bold will terminate a Cook Cycle upon discovery Any fault occurring in a Cook Cycle will be logged in the Fault Code Counter THE CONTROL SYSTEM The Control System is comprised of the components NOTE The part numbers for each component are that signal sense command and switch the oven s given within the parentheses in addition to being various components Figure 4 shows a functional included with the descriptions for each part on the diagram of all the components that make up the following page Control System 24 VDC K2 K3 K6 MECH DUAL MECH RELAY 101272 MECH RELAY 101271 MECH RELAY 101271 SSR RELAY 101284 RELAY 101271 36 40 24VDC 24VDC 24vpc V POWER SUPPLY MONITOR SWITCH 101206 v x 102012 INTERLOCK COMMON 24 VDC BMSC 100443 CONVECTION HEATER COMMAND 2 200 240 SPD 0 10V IR ELEMENT COMMAND 3 VACIN cmp 2 ENABLE 3 11C0M 4 M PRIMARY SWITCH 2 3 PHASE STATUEOK 5 3 INTERLOCK 3 OUT 0 6 CONTROL 4 BOARD SECONDARY
61. heory of operation of the Microwave High Voltage Circuit PRIMARY AND SECONDARY K2 HV TI INTERLOCKS CLOSED F3 FUSE RELAY HV TRANSFORMER p as 20 AMP 1 NC LINE VOLTAGE BLOWN hod o LI a gt CONTROL ar cop 24 VDC T2 NC HV TRANSFORMER CONTROL K3 MONITOR ENS NU 1 LINE VOLTAGE RELAY E 7 L2 i att MONITOR SWITCH 24VDC OPEN 1 CONTROL o dee FIGURE I3 Monitor Circuit shown in failsafe state 21 22 THE MICROWAVE SYSTEM TRANSFORMER OUTPUT VOLTAGE B 2400 V 0 A 2400 V 2400 re VDC 3 2400 Current i Y Flow CAPACITOR CHARGES ON POSITIVE VOLTAGE SWING FIGURE 14 Microwave Circuit Theory of Operation MICROWAVE CIRCUIT THEORY OF OPERATION Figure 14 l The High Voltage Transformer steps up the input voltage to approximately 2400 volts peak 4800 volts peak to peak The High Voltage Capacitor charges to 2400 volts on the positive going voltage via the High Voltage Diode s conduction The High Voltage Transformer plus the charged High Voltage Capacitor supply down to 4800 volts to the Magnetron when the voltage goes negative High Voltage Diode is back biased The Magnetron converts negative input voltage and current to RF energy at 2450 MHz
62. iance must be grounded Connect only to properly grounded outlet See Grounding Instructions found on page ii Install or locate this appliance only in accordance with the provided installation instructions Some products such as whole eggs and sealed containers for example closed glass jars may explode and should not be heated in this oven Use this appliance only for its intended use as described in this manual This appliance should be serviced only by qualified service personnel Contact the nearest authorized service facility for examination repair or adjustment Keep cord away from heated surfaces DO NOT allow children to use this appliance 8 DO NOT use corrosive chemicals or vapors in this appliance This type of oven is specifically designed to heat cook or dry food It is not designed for industrial or laboratory use 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 Supply Cord Replacement found on page ii DO NOT cover or block any openings on the appliance DO NOT store this appliance outdoors DO NOT use this product near water for example near a kitchen sink in a wet basement or near a swimming pool E DO NOT immerse cord or plug in water DO NOT let cord hang over edge of table or counter DO NOT use a water jet for cleaning See the Maintenance section of this manual on page 3 for proper cleani
63. ing 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 CAUTION Never attempt to measure high voltage directly How to check a Diode 1 Disconnect the oven from the power source 2 Isolate the Diode from the circuit 3 Connect the meter leads to the Diode Terminals 4 Infinite resistance open should be indicated in the reverse direction 5 Resistance readings in the forward direction may be indeterminate 6 If continuity in both directions shorted Diode 7 If there is infinite resistance in both direction open Diode 8 Due to the High Voltage Diode consisting of approximately 15 x 1000 volt Diodes in series the forward Diode drop is approximately 9 volts A normal low voltage Ohmmeter will not pro vide sufficient voltage in the resistance ranges to measure an impedance in the forward direction of the High Voltage Diode How to check a Capacitor 1 Disconnect the oven from the power source 2 Isolate the Capacitor from the circuit 3 Fully discharge the Capacitor 4 Connect the Ohmmeter between the Capacitor Terminals The Ohmmeter should momentarily indicate a low impedance and then slowly return to infinite resistance 5 Reverse the Ohmmeter leads and repeat Step 4 6 Check each terminal to case Infinite resistance open should be indicated
64. k diagram of the Convection Circuit Main Convection Heater P N 100661 The Main Convection Heater is an open coil style heater rated at 3300 watts at 208 VAC with a resistance of 13 11 Ohms The Convection Heater is controlled by the K4 Solid State Relay SSR P N 101284 BOTTOM IR CONTROL THE CONVECTION CIRCUIT 4l Convection Motor P N 100882 The Convection Motor is a Brushless DC Switch reluctance type Its top speed is 7200 RPM at 1 HP The Motor is controlled by a proprietary controller Motor Controller BMSC P N 100443 The Motor Controller is proprietary and will only operate the Convection Motor 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 High Limit Thermostat P N 102075 The High Limit Thermostat is a 250VAC 3 Pole manual reset thermostat with a trip point of 572 The Thermostat which interrupts power to both the Convection Heater and the IR Element should never operate during normal operation WH 28 MAIN HX CONTROL WH 30 manu 28 E S 32 d 3l HX ELEMENT i BL540 NC 3300 WATTS 9 22 2 m 13 1 OHMS SSR BL510 100649 12 K5 K4 RUE BOTTOM IR 42 3000 WATTS B
65. l Al 14 4 OHMS OR 9 2 100661 2 E RD 24 E BK 25 gt LI 31 32 a 1 240 M3 WHITE 2 ODE E 4 BMSC SPD yp com 2 ENABLE 3 1 1 0 COM 4 BLWR 2 200 240 STATUEOK 5 MTR 3 VAC IN 1 0 COM 6 LI L2 FIGURE 31 Convection Circuit Block Diagram 42 THE CONVECTION CIRCUIT FIGURE 32 Convection Circuit Assembly and Parts CONVECTION CIRCUIT PARTS Figure 32 97 101688 Screw 8 x 1 2 PTH 98 NGC 1081 Cover Motor Cap 99 100905 Nut 1 4 20 Flange 100 NGC 1025 Assy Blower Motor 101 101688 Screw 8 x 1 2 PTH 102 100661 Heater Convection 103 100443 Controller Motor 104 101284 Relay K4 K5 SSR 105 100592 Buss Fuses 12 Amp 106 102075 High Limit Thermostat Assembly Notes insulation covering Conversion Heater as shown N Gasket Convection Heater P N NGC 1043 not shown for clarity FIGURE 33 Blower Motor Assembly and Parts BLOWER MOTOR PARTS Figure 33 107 700 0306 2 Hub Small 108 NGC 1019 2 Fan Blade NGC Oven 109 NGC 1020 110 NGC 1021 111 700 0284 112 NGC 1024 113 100443 114 NGC 1023 115 102708 116 100882 117 100790 118 NGC 1022 119 101394 120 101394 Ring Fan Blade Plate Blower Cap Shim Seal Sealing Block Blower Washer Wave Spring 30mmOD Clamp Blower Seal
66. mately the same temperature of the airflow thus the grease burns and breaks down into CO and as it passes through the Catalytic Converter The Catalyst will operate most efficiently at temperatures above 475 F 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 commercially available degreasers and cleaners therefore only TurboChef cleaners are to 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 substi tute Use distilled water only IR ELEMENT AND CATALYST REMOVAL Refer to Figure 34 and the instructions below for removing the IR Element and Catalytic Converter Removing the IR Element 1 Disconnect the Heater Wires going to the EMI Filter and the High Limit Thermostat 2 Locate where the IR Element protrudes through the Cook Chamber Walls and remove the Snap Rings Item 130 using Snap Ring Pliers Retain Snap Rings Item 130 and Washers Item 131 Figure 34 3 Locate and remove the Microwave Shield Item 133 by removing the four 4 8 x 1 2 Sheet Metal Screws Item 134 4 Squeeze the IR Element together inside the Cook Chamber
67. nd 2 NOTE If Magnetron failed it is important to understand why Investigate each failed Magnetron If the antenna is strongly discolored look for contamination in the Wave Guides If contamination exists check the Wave Guide Seals Replace any broken Wave Guide Seals THE MICROWAVE SYSTEM ISSUE RESOLUTION F3 Fuse Blown 1 Fuse Blown Replace F3 Fuse and determine why F3 Fuse opened NOTE There are generally only three 3 faults that will cause the F3 Fuse to open They are as follows High Voltage Transformer Primary Winding shorted Replace High Voltage Transformer 2 High Voltage Capacitor shorted or failing Replace the High Voltage Capacitor NOTE failing High Voltage Capacitor will typically cause the High Voltage Transformer supplying power to the failing capacitor to draw excessive current This may open the F3 Fuse if the duration of the excess current is long enough Monitor Circuit Fault Verify operation of all Interlock Switches In addition check the Fault Code Counter If the Monitor Switch opened prior to the Primary and Secondary Interlocks the Control Qo would have recorded the occurrence See page 21 and Chapter 6 Cook Door to trouble shoot the Interlocks Mag 1 or Mag 2 Not Working or Food Not Cooking Evenly Determine which Magnetron is not oscillating by placing a clamp on Amp Meter on the Primary Winding of each High Voltage Transformer and energizing t
68. nd Secondary Interlock Switches fail to operate normally The Monitor Circuit consists of the Primary and Secondary Interlock Switch Monitor Safety Switch Monitor Relay and the F3 Fuse When the Cook Door closes during normal operation the Monitor the Secondary and the Primary Switches close in the order listed above When all switches are closed the Microwave System is allowed to operate THE MICROWAVE SYSTEM If during normal operation either Interlock Switch opens such as when the Cook Door opens the Control System will turn Off the Microwave If the Monitor Switch opens before both the Primary and Secondary Interlock Switches abnormal operation the Monitor Switch de energizes the Monitor Relay When this occurs a dead short is placed across L1 and L2 The short then blows the F3 Fuse which permanently interrupts power to the Microwave System until both the Primary and Secondary Interlock Switches are repaired Figure 13 shows a schematic of the Monitor Circuit Make sure to note the following a Primary and Secondary Switches interlock the High Voltage Control Signal a Normal Operation When the K2 and Relays energize power is supplied to the High Voltage Transformers Abnormal Operation When K2 is energized and K3 is un energized via an opening of the Monitor Switch L1 and L2 short to blow the F3 Fuse and failsafe Figure 14 on the following page details the t
69. ng procedures To reduce the risk of fire in the oven cavity m m Remove wire twist ties from paper or plastic bag in the oven If materials inside the oven should ignite keep oven door closed turn oven off and disconnect the power cord or shut off power at the fuse or circuit breaker panel If smoke is observed switch off or unplug the oven Keep the door closed in order to stifle any flames DO NOT use the cavity for storage purposes DO NOT overcook food Carefully attend the oven if paper plastic or other combustible materials are placed inside the oven to facilitate cooking DO NOT leave paper products cooking utensils or food in the cavity when not in use SAVE THESE INSTRUCTIONS INTRODUCTION PRECAUTIONS TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY To reduce the risk of exposure to excessive microwave energy DO NOT attempt to operate this oven with the door open Open door operations can result in harmful exposure to microwave energy It is important not to defeat or tamper with the safety interlocks DO NOT place any object between the oven front face and the door or allow soil or cleaner residue to accumulate on the sealing surfaces 8 DO NOT operate the oven if it is damaged It is particularly important that the oven door close properly and that there is no damage to the door bent hinges and latches broken or loosened door seals and sealing surfaces DO NOT have the oven adjusted or
70. ng the necessary high voltage 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 F3 Fuse P N 100599 The F3 Fuse is a 20 Amp Class CC fuse designed to blow in the case of an over current scenario such as a High Voltage Transformer or Capacitor failure The Fuse also blows if the Monitor Circuit trips the failsafe High Voltage Capacitors P N 100201 Their rating is 0 91uF 2500 VDC High Voltage Diodes P N 100481 They are rated at 16 kVDC Monitor Relay P N 101271 The Monitor Relay K3 acts as a failsafe device in the High Voltage Circuit In its normal un energized position the Monitor Relay shorts L1 and L2 If the K2 Relay energizes the High Voltage Transformers while the K3 Relay is un energized the F3 Fuse will blow Magnetron Thermostats P N 102070 The Magnetron Thermostats are an open on rise type thermostat These Thermostats are designed to open at 212 NOTE Both Magnetron Thermostats are wired in series Therefore if one opens the Control will switch off both Magnetrons until the Thermostats close The Thermostats are self resetting Magnetron Cooling Fan P N 100083 The Magnetron Cooling Fan supplies cooling air for both Magnetrons The Fan operates at 208 240 VAC and is controlled via the K1 Relay Wave Guide Covers P N NGC 1097 Wave G
71. nge 3 T2 Brown Orange TI ip 3 s Ee 208V Blue Brown Orange Dot FTI Blue 240v 2 12 240 Orange Blue 208V 208V Brown 3 240V keg ME Orange cr Tb 3 A opor ee J SaL e x SIDE OF OVEN 5 FIGURE 21 amp 22 HIGH VOLTAGE DIODE AND MAGNETRON Chapter 5 The Microwave System Page 28 FILAMENT AND HIGH VOLTAGE TERMINALS 56 SERVICE PARTS AND ILLUSTRATIONS FIGURE 23 COOK DOOR REMOVAL AND PARTS Chapter 6 The Cook Door Page 33 Cook Door Parts 44 102809 45 NGC 1060 46 NGC 1061 47 102804 48 102805 49 101381 50 102140 51 102350 52 101191 38 32 x 3 8 CSK Assy Oven Door Hinge Block Right Hinge only Left Hinge 10 32 x 1 2 Hex 55 10 Flat 10 Split Loc Cap Hole j 7 74 277 FIGURE 26 PRIMARY SECONDARY INTERLOCKS ADJUSTMENT PARTS Chapter 6 The Cook Door Page 35 Primary and Secondary Interlock Switch Parts 53 NGC 1076 Actuator Door Screw 8 32 x 1 2 100 CSK 54 102684 55 102921 56 101557 57 102012 58 NGC 1075 Screw 48 32 x 3 8 Screw 44 40 x 1 1 4 Interlock Switches Assy Door Switch APPLY HI TEMP GREASE TO AREA
72. ondary and Monitor Interlock Switches Switches must be actuated by the Cook Door in the following order M S P When the Cook Door opens the order is reversed P S M IR Thermocouple IR Element Type K Thermocouple Thermocouple is embedded in the IR Element The Thermocouple measures the internal sheath temperature of the IR Element Valid IR Set points are between 500 F and 1200 The display indicates 1999 if the Thermocouple is Open EC Thermocouple P N 700 1179 Type K Thermocouple Thermocouple measures the temperature of the Electrical Compartment If the temperature within the Electrical Compartment is above 158 F the Control displays F6 EC Temp CC Thermocouple P N NGC 1140 Type K Thermocouple Thermocouple measures the temperature of the re circulating impingement airflow Valid IR Set points are 450 5409 If the display indicates 999 the Thermocouple is Open BMSC P N 100443 A proprietary Brushless DC Motor Controller designed solely to operate the Convection Motor VDF Display P N 100505 Vacuum Fluorescent Display Keypad P N NGC 1110 3x8 Matrix Membrane Switch Keypad is connected to the Control via a 14 Pin Flat Cable Voltage Sense Module P N 100783 Proprietary device designed to measure incoming line voltage and switch between 208 and 240 VAC operation The device only measures and configures the oven when the oven is switched from the Off State to the On State TEST
73. op view diagram detailing the proper wiring Figure 18 and the Schematic on the inside of page 49 As shown in Figure 18 Transformers are installed mirror opposite and wired 180 out of phase It is essential for longevity that High Voltage Transformers remain 180 out of phase This can be checked by placing a volt meter across terms T1 1 and T2 1 FIGURE 20 Microwave Survey Meter Placement With the Microwave System energized the volt meter will read 208 240 VAC 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 taps 1 amp 2 and 1 amp 3 on each High Voltage Transformer If the voltages are not 208 VAC between 1 amp 2 and 240 between 1 amp 3 the wiring issue must be corrected prior to returning the oven to service NOTE The terminals with the Orange Dot or the Orange Wire always go to Terminal 3 Wiring the Filament Transformers The installation of Filament Transformers is straightforward Filament Transformers are wired in phase and in line Refer to Figure 19 detailing the proper wiring of Filament Transformers To verify correct wiring measure the voltages between Terminal 1 amp 2 and 1 amp 3 on and FT2 The voltages must be 208 and 240VAC respectively NOTE The Terminals with the Orange Dot or the Orange Wire always go to Terminal 3 THE MICROWAVE SYSTEM 27 MEASURING RF L
74. pe out any crumbs that have collected Step 3 Remove the Wire Rack a Wash rinse and sanitize the wire rack NOTE Be sure oven interior is cool prior to removing the wire rack INSTALLATION SPECIFICATIONS AND MAINTENANCE mM See Step 4 Lift Bottom Element Be sure the bottom element is cool prior to lifting NOTE The oven element operates at 1000 F and may cause injury if not allowed to cool properly Step 5 Remove Particles and Spray Oven Interior with TurboChef Oven Cleaner a Using a damp towel remove any large particles from the oven If stubborn stain is present sparingly spray TurboChef Oven Cleaner into the cavity and on the door Allow cleaner to penetrate for five 5 minutes Never saturate the bottom of the oven with water or oven cleaner Step 6 Clean Oven Interior o Using a nylon green scrub pad clean the oven door and cavity CAUTION Do not apply pressure to white Wave Guide Caps Breaking will result in a non warranty service call Step 7 Wipe Out Oven Interior n Wipe oven door and cavity clean using a damp towel n Wipe the element with a clean damp towel INSTALLATION SPECIFICATIONS AND MAINTENANCE Step 8 Clean Area where Lower Access Panel is Located Wipe the area on the outside of the oven where the lower access panel is located E DO NOT spray any chemical in this area Step 9 Lower the Bottom Element and Replace the Wire Rack and Low
75. red for cooking most food items The IR Element is independently controlled via the IR Thermocouple embedded inside the IR Element itself The Catalytic Converter scrubs the air to eliminate VOCs and grease particulates that are liberated during the cooking process It is important to properly care for the Catalyst using only TurboChef Oven Cleaner and distilled water For more detailed information see the Catalytic Converter section below COMPONENTS IR Element 100649 The IR Element a dual coil type heater is located in the bottom of the oven cavity The first coil is the heating coil The second is the IR Thermocouple TIR wire The heating coil outputs 3000 watts at 208 VAC The heating coil s resistance is 14 4 Ohms at room temperature The Thermocouple coil is a Type K Thermocouple with a resistance of approximately 20 Ohms at the splices located approximately 6 inches from the heater and 40 Ohms measured at the extension wires at the I O Control Board The IR Element is controlled via the K5 Solid State Relay P N 101284 and the IR Thermocouple via the I O Control Board Catalytic Converter NGC 1012 The Catalytic Converter a VOC type catalyst is located behind the inside Cook Chamber Wall and is responsible for cleaning the recirculating airflow The Catalyst functions by substantially lowering the combustion temperature of grease entrained in IR ELEMENT AND CATALYTIC CONVERTER the air path to approxi
76. rmostat is not tripped See the High Limit Thermostat information below High Limit Thermostat Thermostat tripped Reset and determine why the Thermostat tripped See Figure 32 Item 106 Look for excess build up of grease inside the oven or any other source for a fire Thermostat is not tripped Check Convection Heater 1 Convection Heater is Defective Replace the Convection Heater and verify the K4 SSR Figure 31 is not shorted across output 2 Convection Heater OK Check the K4 SSR defective Replace K4 OK Verify all wiring F2 Cook Temperature Low 1 Verify Cook Door Operation Cook Door Open Message Verify which switch is not actuating and readjust See page 34 and 36 a Cook Door OK Verify High Limit Thermostat is not tripped See the High Limit Thermostat below High Limit Thermostat Thermostat tripped Reset and determine why the Thermostat tripped See Figure 32 Item 106 Look for excess build up of grease inside the oven or any other source for a fire Thermostat is not tripped Check Main Convection Heater 1 Convection Heater is Defective Replace the Convection Heater and verify the K4 SSR Figure 31 is not shorted across output 2 Convection Heater OK Check the K4 SSR defective Replace n K4 OK Verify all wiring THE CONVECTION CIRCUIT ISSUE RESOLUTION F1 Blower Running Status Bad Determine if Status Indicator
77. se Blown Refer to Fuse Blown on the following page 2 Verify K1 Relay is operating correctly Not Energizing Correct Control issues See Chapter 4 The Control System DANGER Remove F3 Fuse before attempting to measure filament currents Energizing OK Measure Filament Currents to each Magnetron to verify Filament Transformers are OK Place Amp Probe on wires M1 F and then M2 F 1 Current lt 8 Amps on Magnetron 1 Magnetron 2 or both Correct wiring or replace failed Filament Transformer s 2 Current 8 to 10 Amps on M1 F and 2 Filament Transformers OK Go to Step 3 below 3 Verify K2 Relay is operating correctly K2 Not Energizing Correct Control issues See page 21 Figure 13 u K2 Energizing OK Place the oven in Test Mode place a Clamp on Amp Meter on the wire going to the Current Transformer on the I O Control Board Measure and record current when Magnetrons are energized 1 0 Amps High Voltage Transformers 1 and 2 not energizing Repeat Step 1 above If both High Voltage Transformers have failed replace High Voltage Transformers See the Transformer Winding Resistances Table on page 29 to verify failure 2 Less than lt 6 Amps High Voltage Transformers are energizing but the Magnetrons are not drawing full current 14 17 Amps 208 Volts is 17 Amps 240 Volts is 14 Amps Check High Voltage Diodes If Diodes fail replace Diodes If Diodes are OK replace Magnetron 1 a
78. t is detected the Fault Code Counter will increment However if the fault is subsequently cleared by some action whether service related or not the Fault Code Counter will not decrement TO VIEW FAULT CODES To view the Fault Log press the 4 and 6 Keys simultaneously while the oven is in the Off State The oven will display all faults logged Figure 3 Each Fault Log will log up 255 instances before rolling back to zero Press the 0 Key to reset the Fault Code Counter NOTE The Fault Log also displays the Cook Counter which will log up to 65 535 Cook Cycles In order for the Control to log a Cook Cycle the oven must complete the first Event of any given Recipe If a Recipe only has one 1 Event the oven must complete the entire Cook Cycle in order to count the Cook Cycle FAULT CODE DEFINITIONS FI Blower Running Status Bad Fault is displayed when the Blower Controller indicates no running status The Motor and Motor Controller state is monitored continuously in all Modes with special handling in the Self Test and Test Mode If a fault is detected the Control will bounce the oven into the Off State Upon turning the oven On the Control will attempt to restart the Motor If the restart is successful the fault indication will be cleared The fault is also cleared at the onset of cooking or when the blower is tested in the Test Mode FAULT CODES NGCWXXKK KKKKKK S N KKKKKK COOK COUNT F1 BLOWER
79. t to clean and dry the Wave Guide Dirt and contaminates in the Wave Guide can cause premature Magnetron failures 1 Remove the Wave Guide Cover See Wave Guide Cover Replacement on page 24 2 Remove the two 2 right and left most 8 32 x 3 8 screws securing the Wave Guide 3 The Wave Guide should now be loose so as to easily slide out from the right side of the oven If replacing the Wave Guide proceed to Step 6 If cleaning continue on to Step 4 NOTE Take care not to damage the insulation when removing the Wave Guide 4 Thoroughly clean the contaminated Wave Guide using any standard degreaser 5 Thoroughly rinse and dry the Wave Guide before reinstalling FT2 Blue 208V Brown 240V Lg LS Orange 3 e i Orange Dot FTI Blue 208V Brown 240V LN Orange 3 J e FIGURE I9 Filament Transformer Wiring 6 Reinstall the clean or new Wave Guide using the four 4 48 32 x 3 8 mounting screws removed in Step 2 7 Reinstall the Wave Guide Cover HIGH VOLTAGE TRANSFORMER AND FILAMENT TRANSFORMER REPLACEMENT The proper reinstallation of the High Voltage and Filament Transformer is critical as both Transformers are equipped with 208 VAC and 240 VAC taps Wiring the High Voltage Transformer Upon removing a High Voltage Transformer make sure to note where each wire was installed Refer to the t
80. tch Toggle Latch Pin Clevis 03 16 x 1 Lg Bearings Bronze 3 16ID x 5 16OD x 1 4 Lg Screw 4 40 x 1 25 Lg PPHD CRES Screw 48 32 x 3 8 Internal Tooth Sems PPHD SS Plate Door Switch Grease USDA H 1 Food Grade Ring Eclip Assembly Notes Ring Eclip Item 69 is supplied with Item 63 N Spring and Bracket must be lubricated with high temperature pure FM Grease Item 68 3 Assembly to be hand tightened prior to any final adjustment ADJUSTING THE MONITOR SAFETY SWITCH The Monitor Safety Switch is located on the right hand hinge assembly To adjust the Switch follow the steps below NOTE The oven should be cool for this adjustment 1 Ensure the Cook Door is adjusted Refer to Adjusting the Cook Door on page 34 THE COOK DOOR 37 cH a FIGURE 28 Monitor Switch Adjustment and Assembly 2 Open and close the Cook Door several times to 5 Open and close the Cook Door several times to ensure the Door closes smoothly and the Door make certain the adjustment is correct Actuator Item 70 clears the slot in the Flange Reference Figure 26 6 Tighten all screws when adjustment is complete 3 To adjust the Monitor Safety Switch Figure 28 loosen the 8 32 screw and the two 2 4 40 MONITOR SAFETY SWITCH PARTS screws Items 74 and 75 securing the switch Figure 28 70 102804 Hinge Ri
81. tem is Off The Status Indicator section on the following page offers a more detailed description of each indicator 13 THE CONTROL SYSTEM Faults Pressing the Faults Soft Key will display all the accumulated faults in the Fault Log For more information see page 9 F C Changes how the oven s temperature units are dis played The F C Key alternately selects Fahrenheit or Celsius ccc Displays the total number of accumulated Cook Counts for all Recipes PIN Allows the operator to select a new Access Number for entering the Test and Edit Modes IR ELE Pressing the IR ELE Key will turn On the IR Element When pressed the Control will display IR Element On To turn the IR Element Off push the IR ELE Key an additional time IR SI This is a factory setting and should never be altered Consult the factory before changing this value STATUS INDICATORS See Figures 5 and 6 on page 13 Primary Switch closed or open Secondary Switch closed or open Monitor Switch closed or open Magnetron Thermostats closed or open Main Convection Heater off or on IR Element off or on gt m raza Blower Motor Controller enabled or disabled W Microwave Current Less than or greater than 7 Amps Microwave MW Status Indicator is not highlighted backlit when the current is more than 7 Amps The Status Indicators are displayed at the bottom of the display screen when
82. uide Covers protect and seal the Wave Guides from moisture and debris WAVE GUIDE COVER REPLACEMENT The Wave Guide Covers keep moisture and debris out of the Wave Guides If contamination gets into the Wave Guides the life of the Magnetrons may be shortened In most cases the Wave Guides will not be contaminated if the Wave Guide Covers are cracked or broken it depends on how long they have been cracked and how much product has been cooked However if a Magnetron has failed and the Wave Guide Cover is cracked the Wave Guide may need to be removed and either cleaned thoroughly or replaced Figure 17 details the removal and replacement of the Wave Guide Covers To remove the Wave Guide Covers follow the steps below 1 Locate the fourteen 14 8 truss head sheet metal screws securing the broken Wave Guide Cover If the screw heads are dirty it will be necessary to clean the heads thoroughly DANGER Do not strip the screw heads 2 Spray screw heads with a penetrating oil such as WD 40 and allow them to sit for a few minutes Remove the fourteen 14 8 screws using a good 2 Phillips Screw Driver The cover should come loose with gentle pressure DO NOT remove the two 2 right and left most screws These screws secure the Wave Guides to the oven floor Only remove them if the Wave Guide is being removed as well 4 Remove the old Wave Guide Cover and discard unless otherwise specified NOTE It may be n
83. ure and Parts Figure 13 Monitor Circuit Shown in Failsafe State Figure 15 Microwave System Parts Figure 16 Microwave System Parts Figure 17 Wave Guide Cover Wave Guide Removal and Replacement Figure 18 amp 19 High Voltage Transformer and Filament Wirings Figure 21 amp 22 High Voltage Diode and Magnetron Figure 23 Cook Door Removal and Parts Figure 26 Primary and Secondary Interlocks Adjustment and Parts Figure 27 Door Switch Assembly and Parts Figure 28 Motor Switch Adjustment and Assembly Figure 29 Cook Door Assembly Figure 31 Convection Circuit Block Diagram Figure 32 Convection Circuit Assembly and Parts Figure 33 Blower Motor Parts and Assembly Figure 34 IR Element and Catalytic Converter Parts and Assembly Figure 35 NGC Tornado Schematic Figure 36 I O Control Board and Test Point Locations Figure 37 Covers and Miscellaneous Parts Inside 47 47 48 49 49 49 51 52 59 53 54 54 55 55 56 56 57 58 59 60 61 62 63 64 64 66 INTRODUCTION IMPORTANT SAFETY INSTRUCTIONS The following basic safety precautions should be strictly adhered to when using electrical appliances so as to reduce the risk of burns electric shock fire injury to persons or exposure to excessive microwave energy m m Read all instructions before using the appliance Read and follow the Specific Precautions to Avoid Possible Exposure to Excessive Microwave Energy found on page ii This appl

TurboChef Service Manual

Contents

Download Pdf Manuals

Related Search

Related Contents