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Service Manual 04/2010 (Rev. F)

1. SH a REVISIONS COLOR CODE LINE VOLTAGE COLOR CODE HIGH VOLTAGE TENSION acs PR DESCRIPTION DATE APPROVED BL BLUE LINE V 208 240 WH HI VOLTAGE WIRE FOR MAG 1 SAFETY INTERLOCKS 1 BLUE K8 STIRRER STIRRER c CHANGED MAG COOLING FAN CONNECTIONS FROM TOA ON K7RELAY 10 16 08 DoAsT Lo BR BROWN LINE V 208 240 BK HI VOLTAGE WIRE FOR MAG 2 102012 2 OT2 7 o QC3 REMOVED F4 FUSE CIRCUIT MOVED LV SUPPLY WIRE FROM F4 TO F3 TERMINAL 11 6 08 DCASTILLO OR 240 LINE INPUT FOR TAP 3 PRIMARY FAN a 1 a REPLACED F3 FUSE WITH 20 AMP ATMR FUSE ECN 0811003 ON TRANSFORMERS KEYPAD _ is 9247 Po INTERLSER po COOLING REAR NO BROWN 9 o 2 A E GENERAL UPDATES ecn 0909029 POASTILLO BK HI TEMP 240 VAC WIRE 18 53 La ee Po TC3 0433 Be FAN oo NO data 21 Med ona el THERMOSTAT Paa
2. Partition 24 3 618 mm Partition Above Counter Top 24 3 618 mm Above Counter Top L z S TurboChef Grill i5 Oven Deep Fryer 6 12 1 152 mm 305 mm Minimum Minimum Figure 3 Installation Near Open Heat Source 32 0 fe 813 mm 24 0 610mm 17 3 439 mm m 27 8 706 mm 26 625 676 mm m i 24 3 617 mm Ma Al Y 1 5 38 mm 1 l Pi 62 7 1594 mm handle I 44 6 1133 mm O 35 5 902 mm handle m ee 20 5 521 mm e 439 mm 15 8 ho pau 401 mm bankis Y Li def Y VY a a 26 5 673 mm 28 6 726 mm 30 0 762 om ee 31 5 800 mm 32 5 826 mm Figure 4 Oven Carts and Stacking Stand Dimensions NOILWTIVLSNI ANY SNOILLVDI4ID3dS SPECIFICATIONS AND INSTALLATION Voltage Selection For North America oven models the oven will detect 208 or 240 incoming voltage The initial voltage selection is typically completed before the oven is used by the customer However if incoming voltage for the store is different than the preset voltage the operator will be required to select either 208 or 240 after pressing the On Off key to turn on the oven The correct voltage will be enlarged on the screen identifying which option to select Figure 5 below SELECT VOLTAGE
3. A Install or locate this appliance only in accordance with the instructions below Unpacking Instructions l 2 Remove oven from packaging Before discarding packaging check thoroughly for accessories consumables and literature Discard packaging Check cook cavity thoroughly for accessories consumables and literature Discard any packaging in cook cavity Lifting and Placing the Oven N WARNING Oven weighs approximately 275 lbs 125 kg Never lift with fewer than two people A WARNING Lift only using the provided hand grips Never lift the oven by the door handle or by its base DA WARNING The oven must be properly placed on a table or countertop at all times TurboChef will not recognize a fallen oven as a warrantable claim and is not liable for any injuries that may result A WARNING This oven is not intended for built in installation i e installing the oven in any structure that surrounds the oven by five or more sides Be sure to provide a minimum of 2 51 mm clearance for all sides and 16 406 mm clearance for the top 1 Prepare a surface that is at least 30 762 mm deep and capable of supporting 280 lb 127 kg If installing onto an oven cart make sure the wheels casters are locked 2 Position one or more persons at the front and rear of the oven 3
4. To Replace This First Remove This No Covers NOS Merz Top Cover Bi frien siel Items Obstructing Item Part Number Page A 3 Open Top Page A 7 Cover Cover Recess 9 Page A 5 9 Page A 9 Page A 11 Stir Mtr Brkt Top Stirrer Shaft 15 9151 Vv Jetplate Stirrer Stir Mtr Brkt Top Stirrer Shaft Support 15 9152 Y Jetplate Stirrer Thermostat Cooling Fans 102086 Vv Thermostat High Limit 102075 Vv Filter Filter Bracket Thermostat Magnetron Left 102070 y v Magnetron Left Thermostat Magnetron Right 102070 Vv Vv Magnetron Right Transformer Filament NGC 3061 1 Vv Transformer High Voltage NGC 3062 1 v Vent Catalyst Foil Pack RWD 9191 vV Vent Tube Cover Vent Tube Cover 15 9209 Vv Heat Chnl Widmt Voltage Sensor 100783 F Mag FT Diode Bracket Waveguide Left 15 3210 Vv Vv Capacitor WG Gasket a P Mag FT Diode Bracket Waveguide Right 15 3210 Vv Vv Capacitor WG Gasket Mag FT Diode Bracket Waveguide Gasket Left 15 9331 v y Capacitor WG Gasket f Be Mag FT Diode Bracket Waveguide Gasket Right 15 9331 Vv Vv Capacitor WG Gasket Weldment Heat Channel Vent Tube NGC 1397 v See page A 12 through A 13 for removing door hinge components magnetrons magnetron thermostats or waveguides Replacing Items No Cover Removal Required Figures A 1 A 2 NM CAUTION Before removing installing any component make sure it is disconnected from the wire harness
5. Step 6 Adjusting the Time Step 7 Cooking Step 8 Remove Food from Oven Step 9 Additional Cooking Options Step 10 Cooling Down Info Mode Overview of the Info Mode Viewing Cook Counter Time Logs Viewing the Fault Log Viewing the Service Numbers Resetting the Oven MNO RAR DY WN RS RH ha hu N 13 13 13 14 14 Options Screen Setting the Language Setting the Date Time Adjusting the Volume Setting the F2 Alarm Making a Copy of the Oven Menu Updating the Oven Menu Updating the Oven Firmware Test Mode Test Mode Testing Oven Parts Status Indicators Fault Log Turning Diagnostic Mode On Off Manufacturing Mode Microwave Leakage Test How to Use Oven for Testing Microwave Power Test Burn In Serial Number Edit Changing Temperature Measurement Setting Self Test Volt On Erase Default Oven Settings Edit Mode Overview of the Edit Mode Changing Set Temperatures Changing Food Group Item Name Changing Recipe Settings Oven Systems Convection System Blower Motor Bottom Blower Motor Top Blower Motor Controller BMSC Heater Element Jetplate Bottom Jetplate Top Stirrer Motor and Assembly Convection System Troubleshooting Oven Door Removing Reinstalling the Oven Door Adjusting the Oven Door Interlock Switches Adjusting the Door Switches Hinges and Counter Balance Assembly Adjusting the Counter Balance Assembly Measuring RF Leakage for Microwave Safety Oven Door Troubleshooting 14 14 14 14
6. Step 6 Top of gauge should be flush against the top of the bracket Step 7 Tighten Step 8 Loosen Slightly Step 6 Screw fits all the way into the notch NS 90 gt ill Wl HO Me pa Figure 32 Counter Balance Adjustment Measuring RF Leakage for Microwave Safety CDRH Regulation 21 Subpart C 1002 20 N WARNING Procedure requires work while the oven and water loads are hot As a result requires that leakage readings of over 5m W cm must be reported to the manufacturer exercise extreme caution when testing To measure RF leakage 1 Place the oven in WARMING UP MODE page 10 An RF microwave leakage test must be performed steps 1 3 and allow it to warm up to the set at the conclusion of the following service tasks temperature approximately 15 minutes if the Door removal replacement and or adjustment oven starts cold Wave guide removal and or replacement 2 Once the oven has warmed up place the oven Magnetron removal and or replacement in TEST MODE see page 16 From TEST MODE Door switch adjustment and or replacement select MFG Mode Counter balance assembly adjustment and or 3 From the Manufacturing Mode screen select replacement MW Leak Test and follow the instructions on the screen also detailed in following steps AN WARNING If the unit fails the microwave leakage test leakage greater than 5mW cm the oven must be taken out of service immediatel
7. Troubleshooting F1 BLOWER Blower Running Status Bad Do resistance measurements Sa R E ee aos emove obstruction between windings and YES AO NO Pilla a spinning freely or if necessary chassis agree with values on rein f replace blower motor windings resistance motor s table below Be sure to P ia check both the top and ES el a i a bottom blower motors Bean eee Check ihewireh l TEST MODE page 16 NO er NO and if necessary replace Y Replace blower motor s YES Y 1 Locate remote test points on the wiring harness left side 2 Ground QC11 3 top and QC11 6 bottom to chassis to remove the back light from the status indicators 3 While grounded check the terminals on the control wiring plug for 0 10 VDC see schematic page 49 for QC11 reference while incrementing the blower speed in TEST MODE the control board A Replace motor Is DC voltage present throughout all speed pat YES i e z NO controller settings in TEST MODE To From Description Expected Resistance Black Red Winding A B 5 9 7 3 Ohms Black White Winding A C 5 9 7 3 Ohms Red White Winding B C 5 9 7 3 Ohms Black Red or White Green Windings to Chassis Open Figure 39 Motor Windings Resistance Table 37 ONILOOHSATENOYL 38 TROUBLESHOOTING Troubleshooting F2 LOW TMP
8. 2 Open the top cover of the oven ensuring the sup ports are in place and remove the right side cover 3 Disconnect the RTD from the control board and remove it from the heater assembly 4 Place the RTD in ice water for two minutes Take a resistance reading of the RTD 6 IfRTD resistance is not 100 Q RTD is defective and must be replaced n NOTE Use Figure 37 below to determine resistance readings at temperatures other than freezing Smart Card Reader The smart card reader allows the oven operator to load menu or firmware updates from a smart card An oven s menu can also be saved to a smart card For instructions see page 15 Solid State Relay K4 K5 Heater The solid state relay is a 240 VAC dual 40 amp relay K4 right switches power to heater 1 K5 left switches power to heater 2 Speaker The speaker provides audible feedback to the oven operator whenever a key is pressed or a task such as a cook cycle is completed 33 USB Port The USB port allows the oven operator to load menu or firmware updates from a USB drive An oven s menu can also be saved to a USB drive For instructions see page 15 Voltage Sensor For North America oven models the oven will detect 208 or 240 incoming voltage The initial voltage selection is typically completed before the oven is used by the customer However if incoming voltage for the store is different than the preset voltage the operator will
9. 2 Use the numeric keypad to enter the month day and year followed by the hour and minute NOTE The clock is a 24 hour clock e g 20 30 8 30 PM 3 Select Save to save your changes or Cancel to cancel and exit the screen NOTE The oven will not retain the time if it is left unplugged for two or more weeks Adjusting the Volume From screen 2 of the INFO MODE Figure 16 page 13 press the L5 soft key to adjust the beeper volume SET DATE TIME MM DD YY HH MM 09 29 09 20 30 CANCEL Figure 20 Set Date Time Setting the F2 Alarm Under normal operation the F2 alarm will terminate a cook cycle if the CC temperature falls below 84 F 47 C of the set point Turning off the F2 alarm will prevent a cook cycle from being terminated if the fault is discovered In either event the fault will be logged for service purposes and should necessitate a service call To turn the F2 alarm on or off press the R2 soft key from the Info 2 screen Figure 16 page 13 Making a Copy of the Oven Menu From screen 2 of the INFO MODE Figure 16 page 13 press the R1 soft key to access the Load Menu screen NOTE This feature can be turned on or off via the Options screen Figure 19 page 14 To save a copy of the oven menu to a smart card 1 Insert the smart card Figure 21 2 Press the L2 soft key Save to Card 3 Verify the oven beeps and reads FINISHED To save a copy of t
10. 706 mm Depth 26 625 676 mm Part Number NGC 1217 3 Height 32 813 mm Width 27 8 706 mm Depth 26 625 676 mm TurboChef Stacking Stand Part Number i5 9369 Height 44 6 1133 mm Width 32 5 826 mm Depth 26 5 673 mm NOTE The stacking stand can only be used with the 17 3 439 mm oven cart P N NGC 1217 2 Oven Restraint Kit Part Number TC3 0242 A WARNING The Oven Restraint Kit will not prevent the oven from falling off a counter topif the oven is pulled off or allowed to slide off the edge Installation instructions are included with the kit ChefComm Pro CON 7006 ChefComm Pro empowers any user of a TurboChef oven to easily and efficiently create menu settings on a computer and transfer them to an oven via smart card or USB device ChefComm Limited CON 7016 ChefComm Limited is a read and transfer only version of ChefComm Pro that helps ensure carefully crafted settings are easy to distribute glob ally while providing the peace of mind that they will not be altered Counter Top Table
11. MW LEAK TEST SELF TEST MW POWER TEST VOLT ON BURN IN ERASE DEFAULT SERIAL NUMBER EDIT FAHRENHEIT 382F PSM t HBT Figure 23 Manufacturing Mode L1 SERIAL NUMBER EDIT L2 i5 D10001 EB L4 L5 CANCEL Figure 24 Serial Number Edit 17 Burn In Press the L3 soft key Figure 23 to initiate a 25 minute burn in This feature helps ensure all cavity walls reach thermal equilibrium before testing is conducted Serial Number Edit Press the L4 soft key Figure 23 to access the Edit Serial Number screen Figure 24 To edit the serial number Use the number letter keys to change a character After one second the cursor will advance to the next character Press the R3 soft key to advance to next character Press the L3 soft key to return to previous character Press the R5 soft key to save the changes or the L5 soft key to cancel Changing Temperature Measurement Setting Press the L5 soft key Figure 23 to change the temperature to either Fahrenheit or Celsius Self Test Press the R1 soft key Figure 23 to access Self Test From the Self Test screen Figure 25 LI soft key initiates a comprehensive self test The oven will check the door switches blowers magnetrons and heaters in sequence L2 soft key initiates a door switch test only L3 soft key initiates a blower test only L soft key initiates a magnetron test only L5 soft key initiates a heater
12. TURBO CHEF Service Manual FOR THE TURBOCHEF i RAPID COOK OVEN 2008 2010 TurboChef Technologies Inc For further information call 800 90TURBO or 1 214 379 6000 The information contained in this manual is important for the proper installation use maintenance and repair of this oven Follow these procedures and instructions to help ensure satisfactory baking results and years of trouble free service Errors descriptive typographic or pictorial are subject to correction Specifications are subject to change without notice Please carefully read this manual and retain it for future reference 2008 2010 TurboChef Technologies Inc Table of Contents Safety Instructions General Safety Information Reducing Fire Risk Grounding Instructions Power Cord Replacement Precautions to be Observed Before and During Servicing to Avoid Possible Exposure to Excessive Microwave Energy RF Interference Considerations Specifications and Installation Theory of Operation Certifications Dimensions Oven Construction Electrical Specifications Unpacking Instructions Lifting and Placing the Oven Installation Near Open Heat Source Optional Installation Items Voltage Selection Ventilation Requirements Daily Maintenance Oven Controls and Cooking Oven Controls Cooking Step 1 Turn the Oven On Step 2 Select Cook Temperature Step 3 Warming Up Step 4 Soaking Step 5 Ready to Cook or Idle
13. Check in TEST MODE see page 16 Is the high limit Era Is the heater defective Check in See page 37 thermostat tripped TEST MODE see page 16 to troubleshoot F1 BLOWER Blower Running Status Bad YES YES NO Is the solid state relay Reset page 32 and eS defective or damaged determine why it ar tripped excess x build Verify the solid state NO grease buildup etc relay is not shorted l across output YES Is the wiring from the solid Y state relay to the control board OK See page 49 for schematic YES NO y 1 Replace the solid state relay Replace the control board Correct wiring Troubleshooting F9 CC TEMP Cook Cavity Temperature High Ensure the oven is cleaned daily see pages 7 8 If this fault frequently occurs Determine if large amounts of grease laden food are being cooked and if so recommend smaller portions be cooked per cook cycle Non Fault Code Troubleshooting This section provides troubleshooting tips for issues that may occur independently of an oven fault Troubleshooting No Keypad Input YES i Is the keypad cable properly connected to the Replace the keypad If the problem persists replace the control board control board Correct wiring Troubleshooting Cook Door Open Message when Door is Closed
14. Relay K3 Monitor The K3 relay is a 240 VAC 30 amp double pole double throw 24 VDC relay coil It shorts L1 and L2 if the monitor switch opens before the primary or secondary switches Relay K6 Voltage The K6 relay is a 30 amp three pole double throw 24 VDC relay coil Utilized in North America only it switches between 208 and 240 VAC on the high voltage transformer and filament transformer taps depending on incoming voltage Through the voltage sensor the oven defaults to the 240V position and switches to 208 if less than 222 volts is detected 230V 400V international ovens and all Japan models utilize the N C contacts of this relay to power the magnetron circuit Relay K7 Magnetron Cooling Fan The K7 relay is a 240 VAC 30 amp double pole double throw 24 VDC relay coil It switches power to the magnetron cooling fans when the magnetron filaments are actuated The control board switches off power after 4 minutes 15 seconds NOTE The 4 15 timer starts over each time the magnetron filaments are actuated Relay K8 Stirrer Motor The K8 relay is a 240 VAC 30 amp double pole double throw 24 VDC relay coil It switches power to the stirrer motor RTD The RTD is a resistance temperature detector used to detect the cavity temperature If the display reads 999 F C the RTD is open resulting in an F7 fault See page 41 for troubleshooting Testing Procedure 1 Disconnect power from the oven
15. 208 VAC 240 VAC Figure 5 Selecting Voltage Ventilation Requirements The TurboChef model i5 oven has been approved by Underwriter s Laboratory for ventless operation UL 710B KNLZ listing for all food items except for foods classified as fatty raw proteins Such foods include bone in skin on chicken raw hamburger meat raw bacon raw sausage steaks etc If cooking these types of foods consult local HVAC codes and authorities to ensure compliance with ventilation requirements NOTE In no event shall the manufacturer assume any liability for damages or injuries resulting from installations which are not in compliance with the instructions and codes previously listed Daily Maintenance Daily Maintenance Supplies and Equipment The following steps will help maintain your i5 Oven TurboChef Oven Cleaner Part Number 103180 Use only TurboChef Oven Cleaner and Oven Guard TurboChef Oven Guard Part Number 103181 The use of any other cleaning products can damage Nylon scrub pad cleaning towel disposable gloves critical oven components resulting in a protective eyewear dust mask optional pair of non warranty service call tongs wrapped with towel optional see step 11 Step 1 Prepare the Oven A WARNING The oven operates at approximately 500 F 260 C and may cause injury if not allowed to cool properly Turn off the oven by pressing the On Off key Slightly open the oven door Coo
16. 37 38 39 40 40 41 41 42 42 43 43 44 45 46 47 48 49 A 1 A 3 A 5 A 7 A 9 A 11 A 12 IMPORTANT SAFETY INSTRUCTIONS WARNING When operating this oven strictly adhere to the following safety precautions to reduce the risk of burns electric shock fire injury damage to oven or property near oven or possible exposure to excessive microwave energy General Safety Information Y Read all instructions before using this appliance Y Read and follow the specific Precautions to be Observed Before and During Servicing to Avoid Possible Exposure to Excessive Microwave Energy found on page ii v This appliance must be grounded Connect only to properly grounded outlet See Grounding Instructions found on page ii Y Install or locate this appliance only in accordance with the provided installation instructions v Some products such as whole eggs and sealed containers e g closed glass jars may explode and should not be heated in this oven v Use this appliance only for its intended uses as described in this manual v This appliance should be serviced only by qualified service personnel Contact the nearest authorized service facility for examination repair or adjustment Y Keep cord away from heated surfaces Y Liquids such as water coffee or tea are able to be overheated beyond the boiling point without appearing to be boiling Visible bubbling or boiling when the container is removed from the microwave ov
17. Depending on the voltage of the battery voltage between 5 7 VDC should be present in only one direction and 0 0 1 VDC in the other direction 29 SWALSAS NJAO OVEN SYSTEMS Magnetrons Figure 35 Magnetrons supply the RF energy at 2 45 GHz and begin to oscillate when they are supplied with approximately 4 1 kVDC at approximately 350 mA During operation each magnetron will output a nominal 1 kW of power If replacement is required conduct a microwave leakage test pages 25 26 after installation of new magnetron FILAMENT AND HIGH VOLTAGE TERMINALS an Figure 35 Magnetron Testing a Magnetron for an Open Shorted Filament A DANGER The only safe way to test a magnetron is by a resistance test of its filament Never attempt to measure the magnetron using any other method while the microwave system is on Death or serious injury could occur 1 Disconnect the AC power source 2 Remove the top cover of the oven and discharge the high voltage capacitors 3 Isolate the magnetron from the circuit by removing the wires from the F and FA terminals Figure 35 4 An ohmmeter connected between the filament terminals F FA should indicate a reading of less than 1 ohm Figure 35 5 A continuity check between either filament terminal and the magnetron chassis should indicate an infinite resistance
18. In Figure 30 the cursor is in the Time column 2 Use the number keys to adjust event settings Time 0 100 in 1 increments The sum of the percentages across eight events must equal 100 Top Blower 10 100 in 10 incr Bottom Blower 10 100 in 10 incr Microwave 0 100 in 10 incr 3 Press the R4 Time soft key or press the Down key to move the cursor to the total time field 4 Use the number keys to adjust the cook time 5 Press the R3 soft key to save changes NOTE For the save to take effect the cursor must be advanced past the field that was last edited 6 If desired press the R5 soft key to test the new settings The oven may require time to warm up 7 When all editing is complete return to the Options screen and turn off the EDIT MODE see page 14 to allow access to regular cook mode Chicken and Fowl FZN Wings 15 pcs TIM EVENT TIM TOP BOT TOTALTIME 01 40 TOTAL 100 SP 450F CC 455F Figure 30 Recipe Edit Screen Oven Systems Convection System The convection system is designed to rapidly heat clean and recirculate air into the cook cavity This section contains information about the following components Blower motor bottom Blower motor top Blower motor controller Heater element Jetplate bottom Jetplate top Stirrer motor and assembly For information on accessing and removing parts see the Appendix Blower
19. except Japan Capacitor rating is 1 15uF 2500 VDC for all 50 Hz installations Capacitor rating is 0 85uF 2500 VDC for 60 Hz Japan installations Testing a Capacitor DANGER Never attempt any measurement of the capacitors while they are enabled Lethal voltage will be present Measure only in compliance with these procedures 27 Disconnect the oven from the power source Remove the top cover of the oven Fully discharge the capacitor Isolate the capacitor from the circuit Check for an open or shorted capacitor by placing ohmmeter leads between the capacitor terminals Rising escalating ohm readings capacitor OK Constant infinite resistance capacitor open Constant very low resistance capacitor shorted 6 If the capacitor is not open or shorted set the meter to measure capacitance and again place the leads between the capacitor terminals The meter reading should equal the label value plus or minus 10 If not replace the capacitor WMA HA OD NN Filament Transformers For better operation and reliability the oven uses separate transformers in order to preheat the magnetron filament The control energizes the filament transformers for approximately five seconds prior to energizing the Microwave Circuit via the high voltage transformers When in operation the filament transformers supply approximately 3 15 VAC at 10 amps to each magnetron filament The filament transformers
20. open N CAUTION Be careful to not allow debris into the wave guides when servicing the magnetrons Stirrer Motor and Assembly The stirrer is responsible for evenly distributing hot air and microwaves that are launched from the top of the oven into the cook cavity The stirrer is driv en by a motor that remains on during a cook cycle or when the oven is in TEST MODE The stirrer motor turns off when the cook cavity temperature recedes below 150 F 66 C The stirrer motor can be tested in TEST MODE see page 16 N CAUTION Be careful to not allow debris into the waveguides when servicing the stirrer assembly Waveguides The waveguides channel microwaves into the cook cavity If debris or contamination gets into the waveguides the life of the magnetrons may be shortened Be careful to not allow debris into the waveguides when servicing the magnetrons or stirrer assembly Microwave System Troubleshooting The following faults may occur in relation to the microwave system F3 Magnetron Current Low see page 39 F5 Magnetron Over Temperature see page 40 The following issues may occur in relation to the microwave system Electrical component failure blank or scrambled display damaged control board etc Food not cooking properly see page 45 Control System This section contains information about the following components Control board Display Electrical compartment cooling fans E
21. 12 amp 100592 Vv Fuse F3 12 amp 100592 Vv Fuse F3 20 amp 100599 Vv Fuse F4 12 amp 100592 Vv Fuse Holder 103548 Vv Fuses Hand Grip 15 9256 Vv Heat Shield Support Bracket 15 9224 v Heat Slinger 102708 v Blower Motors Heater Assembly 15 3214 Vv RTD Heater Helical 15 9381 Vv RTD Heater Plate Helper Spring Interlock Switch Left 15 9397 Vv Helper Spring Interlock Switch Right i5 9397 v See page A 12 through A 13 for removing door hinge components magnetrons magnetron thermostats or waveguides A 1 SLNINOdWOD N3AO NIDVIdd XIGNAddV A 2 APPENDIX REPLACING OVEN COMPONENTS To Replace This First Remove This Item Part Number No E eee E j rep ENG ld Er ao Page A 3 Page A 5 Page A 7 Page A 9 Page A 11 Access Hinge Bracket Slide LHS 15 9196 Vv Vv Door Switches Hinge Bracket Slide RHS 15 9195 Vv Vv Door Switches Hinge Cam Weldment LHS 15 9313 Vv Vv Door Switches Hinge Cam Weldment RHS 15 9314 Vv Vv Door Switches Hinge Guide Switch Slide Lower 15 9316 Vv Vv Door Switches Hinge Guide Switch Slide Upper 15 9315 Vv Vv Door Switches Hinge Gusset LHS 15 9178 Vv Vv Door Switches Hinge Gusset RHS 15 9179 Vv Vv Door Switches Hinge Module Base 15 9193 Vv Vv Door Switches Hinge Torsion Bar 15 914
22. 15 15 15 15 16 16 16 16 17 17 17 17 17 17 17 18 18 19 19 20 20 21 21 21 21 21 21 21 21 22 22 22 22 24 24 24 24 25 26 Microwave System Capacitors Testing a Capacitor Filament Transformers Wiring the Filament Transformers High Voltage Transformers Wiring the High Voltage Transformers Testing a Filament or High Voltage Transformer High Voltage Diodes Testing a High Voltage Diode Magnetrons Testing a Magnetron for an Open Shorted Filament Stirrer Motor and Assembly Wave Guides Microwave System Troubleshooting Control System Control Board Display Electrical Compartment Cooling Fans Electrical Compartment Cooling Fan Thermostat Electrical Compartment Thermocouple EMI Filter Fuses High Limit Thermostat Keypad Magnetron Cooling Fans Magnetron Thermostats Power Supply Relay K1 Filament Relay K2 Anode Relay K3 Monitor Relay K6 Voltage Relay K7 Magnetron Cooling Fan Relay K8 Stirrer Motor RTD Smart Card Reader Solid State Relay K4 K5 Heater Speaker USB Port Voltage Sensor Wire Harness Control System Troubleshooting Filtering System Catalytic Converter Drain Pan Air Filter Vent Catalyst Filtering System Troubleshooting 27 27 27 27 27 28 28 28 28 29 30 30 30 30 30 31 31 31 31 31 31 31 31 32 32 32 32 32 32 32 32 32 32 32 33 33 33 33 33 33 39 33 34 34 34 34 34 34 Troubleshooting Overvi
23. Amps Max Input 10000 watts Plug NEMA 6 50P Multi Phase i5 DL USA model i5 9500 14 DL 208 240 VAC 60 Hz 30 Amps Max Input 9500 11500 watts Plug NEMA 15 30P i5 BD model i5 9500 16 BD 220 VAC 60 Hz 28 Amps Max Input 10000 watts Plug IEC 309 4 pin iS LD model i5 9500 15 LD 220 VAC 60 Hz 28 Amps Max Input 10000 watts Plug NEMA 15 30P i5 EW model i5 9500 4 EW 400 VAC 50 Hz 19 Amps Max Input 10000 watts Plug IEC 309 5 pin i5 AU model i5 9500 5 AU 400 VAC 50 Hz 19 Amps Max Input 10000 watts Plug Clipsal 5 pin iS UK model i5 9500 2 UK 230 VAC 50 Hz 48 Amps Max Input 10000 watts Plug IEC 309 3 pin iS JK model i5 9500 8 JK 50 Hz i5 9500 10 JK 60 Hz 200 VAC 50 or 60 Hz 46 Amps Max Input 9000 watts Plug PSE marked 3 blade iS KW model i5 9500 12 KW 400 VAC 60 Hz 19 Amps Max Input 10000 watts Plug IEC 309 5 pin iS ED model i5 9500 3 ED 230 VAC 50 Hz 28 Amps Max Input 10000 watts Plug IEC 309 4 pin i5 SD model i5 9500 13 SD 230 VAC 60 Hz 28 Amps Max Input 10000 watts Plug IEC 309 4 pin i5 JD model i5 9500 9 JD 50 Hz i5 9500 11 JD 60 Hz 200 VAC 50 or 60 Hz 25 Amps Max Input 10000 watts Plug PSE marked 4 blade North America models include a voltage sensor that detects 208 or 240 VAC The voltage sensor does not compensate for lack of or over voltage installations Figure 2 Hand Grip Locations
24. Cook Temperature Low Reset and determine why it tripped excess grease buildup etc Figure 36 page 32 YES Is the high limit thermostat tripped NO Is wiring from the solid state relay to the I O control board OK See page 49 for schematic NO YES NO I Is the RTD functioning properly Correct wiring NO Ensure wiring is correct If necessary replace RTD YES i Is the customer over loading the cavity with frozen product c YES gt NO N Replace the I O control board Is either of the heater ele ments defective heaters should have a resistance of 14 4 Ohms NO YES i Replace the defective heater Y defective Is the solid state relay YES y Replace the solid state relay Enable the F2 Alarm Off mode see page 14 This will allow the oven to continue to operate if the temperature drops during an overload condition Troubleshooting F3 MAG CURR Magnetron Current Low Energize the mag netron circuit from Test Mode page 16 Intl Is the oven International or U S f U S Is the K6 mechanical relay in good working order NO YES Are there 10 amps 1 present on the current transforme
25. Excessive Microwave Energy a DO NOT operate or allow the oven to be operated with the door open b Make the following safety checks on all ovens to be serviced before activating the magnetron or other microwave source and make repairs as necessary 1 interlock operation 2 proper door closing 3 seal and sealing surfaces arcing wear and other damage 4 damage to or loosening of hinges and latches 5 evidence of dropping or abuse c Before turning on microwave power for any service test or inspection within the microwave generating compartments check the magnetron wave guide or transmission line and cavity for proper alignment integrity and connections d Any defective or misadjusted components in the interlock monitor door seal and microwave generation and transmission systems shall be repaired replaced or adjusted by procedures described in this manual before the oven is released to the owner e A microwave leakage check to verify compliance with the Federal Performance Standard should be performed on each oven prior to release to the owner Refer to pages 25 26 for leakage test procedures RF Interference Considerations The i5 oven generates radio frequency signals This device has been tested and was determined to be in compliance with applicable portions of FCC part 18 requirements and to the protection requirements of Council Directive 89 336 EEC on the approximation of the laws of the Member States relati
26. Inspect Replace wiring between K2 relay terminal 4 and T1 1 NO and between K2 relay terminal 6 and T2 3 U S 240 T2 2 Lag U S 208 or International on the high voltage transformers filament transformer s Replace the control board capacitor s Is voltage leaving the K2 anode relays on terminals 4 6 YES i Test the high voltage transformers page 28 Are the transformers functioning properly YES f Test the filament transformers page 28 Are the filament functioning properly T Replace the NO TES a high voltage 7 t diode s Test the capacitors page 27 Are the capacitors functioning properly YES L Test the high voltage diodes page 29 Are the high voltage diodes functioning properly Replace the K2 anode relay YES Replace the magnetron s 39 DNILOOHSFIANOUL 40 TROUBLESHOOTING Troubleshooting F4 MONITOR Door Monitor Defective Replace the F3 or if applicable the F4 Is the F3 or if applicable the F4 fuse f NO PP YES fuse Are the switches open Ly ing in the correct sequence P S M To access TEST MODE or for Adjust the door switches See page 24 info on status indicators NO gt for instructions From the coo
27. No Cover Removal Required Figure A 2 Door Assembly Detail Figure A 3 Opening Top Cover Required Replacing Items Opening Top Cover Required Figure A 3 A DANGER Before replacing any oven component ensure the oven is removed from any power source Replacing a component while the oven is plugged in can result in serious injury or death IN CAUTION Before removing installing any component make sure it is disconnected from the wire harness where applicable DA NOTE Hardware listed is required for installing component to oven To open the top cover L 2 Open the oven door The top cover is secured to the heat shield via 2 sheet metal screws above the oven door Remove these screws Open the top cover Secure the support arms in place A 5 SININOdWO NJAO DNIDV 1434 XIGNAddV A 6 APPENDIX REPLACING OVEN COMPONENTS ae Item Description Item Part Number Hardware Description Hardware Part Number s 1 Cover Top 15 9243 Screw 10 32 x 3 8 lg PFLH 100 Deg SS 1101401 qty 2 2 Fuse F1 12 amp 100592 None None 3 Fuse F2 12 amp 100592 None None 4 Fuse F3 12 amp t 100592 None None 5 Fuse F3 20 amp 100599 None None 6 Fuse F4 12 amp 100592 None None 7 Fuse Holder 103548 Screw 8 32 x 3 8 PPHD Int Sems SS 102921 qty 4 8 Heat Shield Support Bracket 15 9224 Screw Torx Head Sh Mtl 3 8 Cres 10275
28. None x l 2 Cover Right Side 15 9302 Screw 8 Serr PPHD Truss Black Oxide 101691 qty 5 D 3 Heater Assembly 15 3214 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 1101688 qty 10 4 Heater Helical qty 2 per oven i5 9381 Screw 8 32 x 3 8 PPHD INT SEMS SS 102921 qty 3 per heater QO Z 5 Helper Spring Interlock Switch i5 9397 None None G 6 Interlock Switch Monitor 102012 Screw 4 40 x 1 PPH Sems 102903 qty 2 Q m 7 Interlock Switch Secondary 102012 Screw 4 40 x 1 PPH Sems 102903 qty 2 Z 8 Mounting Bracket Interlock Switch 15 9272 Screw 10 32 x 3 4 lg PPH Sems Int Th 1102937 qty 2 a 9 RTD Cook Cavity HHC 6517 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 2 O NOTE For more interlock switch detail see Figure A 11 page A 13 t NOTE The Heater Assembly service kit i5 3214 is only used for replacing the older style finned un heater assembly The service kit includes two Helical Heaters and the Heater Plate A 12 APPENDIX REPLACING OVEN COMPONENTS Replacing Items Removing Opening Multiple Covers Required Figures A 10 A 11 A A A DANGER Before replacing any oven component ensure the oven is removed from any power source Replacing a component while the oven is plugged in can result in serious injury or death CAUTION Before removing installing any component make sure it is disconnected from the wire harness where applicable NOTE Hardware listed is required f
29. be required to select either 208 or 240 after pressing the On Off key to turn on the oven The correct voltage will be enlarged on the screen identifying which option to select Wire Harness The wire harness distributes power to the oven s electrical components See page 49 for a schematic Control System Troubleshooting Potentially any fault may occur in relation to the control system See section Fault Code Troubleshooting pages 37 42 Potentially any one of the issues diagnosed in the section Non Fault Code Troubleshooting may occur in relation to the control system See section Non Fault Code Troubleshooting pages 43 48 oF 0 20 40 60 80 100 120 140 160 180 200 0 90 030 97 390 101 740 106 070 110 380 114 680 118 970 123 240 127 500 131 740 135 970 200 135 970 140 180 144 380 148 570 152 740 159 900 161 040 165 170 169 290 173 390 177 470 400 177 470 181 540 185 602 189 640 193 670 197 690 201 690 205 672 209 640 213 600 217 540 600 217 540 221 470 225 380 229 280 233 170 237 040 240 900 244 740 248 570 252 380 256 180 C 0 10 20 30 40 50 60 70 80 90 100 0 100 000 103 902 107 790 111 670 115 540 119 400 123 240 127 070 130 890 134 70 138 500 Q
30. cleaning and operating the i5 oven If you have questions that are not addressed in this manual contact Technical Service 800 90 TURBO 1 214 379 6000 or your Authorized Distributor Certifications cULus UL EPH T V CE FDA Dimensions Oven Dimensions Height 24 3 618 mm Width 27 2 691 mm Depth door closed 28 25 718 mm Depth door open 43 4 1102 mm Weight 275 Ibs 125 kg Cook Cavity Dimensions Height 10 254 mm Width 24 610 mm Depth 16 406 mm Volume 2 22 ft 63 liters Clearances Top 16 406 mm Sides 2 51 mm NOTE This oven is not stackable Oven Construction Exterior Two tone stainless steel front top and sides 304 stainless steel removable grease pan Ergonomic door handle Rubber seal for surface mounting Side handles for lifting Interior 304 stainless steel interior Fully insulated cook chamber Removable rack with dual setting option Top and bottom jetplates NOILVTIVLSNI ANY SNOLLVDI4ID34S SPECIFICATIONS AND INSTALLATION Electrical Specifications TurboChef recommends a Type D circuit breaker for all installations outside the US Single Phase iS US model i5 9500 1 208 240 VAC 60 Hz 48 Amps Max Input 9500 11500 watts Plug NEMA 6 50P iS BK model i5 9500 6 BK 220 VAC 60 Hz 48 Amps Max Input 10000 watts Plug IEC 309 3 pin iS LA model i5 9500 7 LA 220 VAC 60 Hz 48
31. exposed to cleaning chemicals containing phosphates NaOH silicates Na and Potassium Salts These chemicals are found in most commer cial degreasers and cleaners therefore use only TurboChef Oven Cleaner when cleaning the oven Drain Pan The drain pan collects debris as it is flushed through the bottom of the cook cavity Older i5 oven models utilize a drain pan and lower front panel that allows removal of the drain pan without removing the front cover This style of drain pan and lower front panel are obsolete They have been replaced with a new covered lower front panel i5 9282 and a recessed drain pan i3 9252 The recessed drain pan is functionally the same as the old style drain pan and can be used with the old style lower front panel however there are visual differences since it is designed to fit with the new covered lower front panel The new covered lower front panel is not compatible with the old style drain pan If the old style lower front panel is replaced with the new covered lower front panel the old style drain pan must be replaced with the recessed drain pan Air Filter The filter is located on the back of the oven It helps prevent debris from getting into the electrical compartment This component requires scheduled maintenance and occasional replacement as it must be kept clean and in good working condition to ensure proper air circulation to the electrical components of the oven See page 8 ste
32. f 4116 7 8 9 po 31617111 5158 p i i 4 6 l A2 B2 rn TURBOCHEF TECHNICAL SUPPORT i o 7 E 3PHASE 3m Kl lo SINGLE KA K5 SOLIDSTATE 102075 800 908 8726 USA i LOAD j i RELAY o IT Fe DELTA de NGe3005 214 379 6000 INTERNATIONAL A 599 zo ja A Na ZO i l pe ol l d l 4 WIRE INPUT JUMPER 1234 EMI FILTER WYE EMI FILTER Dii seals 593 20 3 WIRE INPUT A ce B SIGNATURE DATE 50A IREINPUT 50A 1 JUMPER USED DRAWN 100546 ae 100546 230VAC 208 240vac FORSINGLE EMI PIETER 230VAC 208 240VAC GREG HAUN 08 14 2006 Parte 59220 380 415VAC EF s33zo0 s07 ane PHASE ONLY 100546 Sone e i f CHECKED SCHEMATIC i5 l 50HZ oo a La pi SY z0 En Liz 03 01 2007 MULTIPHASE 230 380 415 VAC 50 HZ i BLK boj OX ba 00 on ENGINEER MULTIPHASE 208 240 VAC 60 HZ ERN al NE BRN Tr it MU l DE A i BLU 0_0 e BLK m i is CODE IDENT NO DRAWING NO if le GRN Q Bai GRN gt NEMATSS0B hail za IEC3 PIN NEMA6 50P i5 9100 AAA ea MI De el e IA GA APPLICATION Beste 8 7 6 5 4 4 3 2 1 Figure 39 i5 Oven Schematic 49 DILWWAHDS NJAO This page intentionally left blank Appendix Replacing Oven Components Comprehensive Table of Oven Components N NOTE For hardware see the illustrations contained in this appendix IN DANGER Before replacing any oven component ensure the oven is removed from any power source Replacing a component while
33. five to the left and right of the display Press a soft key to select an option adjacent to that key on the display NOTE Soft keys are labeled L1 L5 and RI R5 in this manual where applicable for identification purposes 5 Up and Down Keys When the oven is ready to cook i e warmed up and waiting for a cook command press the Up or Down key to view additional food groups or items When the oven is in the Info Mode see page 13 press to navigate between screens 1 and 2 When editing a food item press to navigate between editable fields Figure 30 page 20 6 Back Stop Key When the oven is cooking press the Back Stop key to immediately terminate a cook cycle When the oven is ready to cook i e warmed up and waiting for a cook command or in the Info Mode see page 11 press the Back Stop key to return to the previous screen 7 Enter Key Press the Enter key when saving changes to food item settings Figure 30 page 20 or whenever instructed by the oven screen 8 Numeric Keypad Use the numeric keypad to enter access passwords or modify cook settings Figure 30 page 20 The numeric keypad also contains a Back Stop key and an Enter key which are functionally identical to Items 5 and 6 ONIMOOD ANY S1OY LNOD NJAO 10 OVEN CONTROLS AND COOKING Cooking The oven is preprogrammed with recipe settings at the time of manufacture and is ready to operate out of the box If these settings are
34. installing any component make sure it is disconnected from the wire harness where applicable N NOTE Hardware listed is required for installing component to oven To remove the top cover 1 Open the top cover see page A 5 for instructions 2 Remove the hinge screws located near the back of each side of the top cover 3 Detach the support braces from the oven frame The should remain attached to the top panel DA CAUTION When detaching the support braces be sure to support the top cover to prevent it from collapsing onto the components in the electrical compartment 4 Remove the top panel and place it somewhere safe N CAUTION The top cover has critical components attached Handle it carefully Figure A 4 Removing Top Cover Required Figure A 5 Stirrer Motor and Assembly Detail A 7 SININOdWO NAO NIDV Idd XIGNAddV A 8 APPENDIX REPLACING OVEN COMPONENTS Figure A 6 Top Cover Detail aan Dr Item Description Item Part Number Hardware Description Hardware Part Number s 1 Capacitor High Voltage 100232 None None 2 Capacitor Clamps 100134 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 2 3 Control Board 15 3208 1 Nut Keps Hex 6 32 Ext Tooth Cres 102961 qty 4 4 Cooling Fan Exterior TC3 0433 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 2 5 Cooling Fan Interior TC3 0433 Screw 8 32 x 2 1 2 Lg
35. pan fits within Empty clean and reinstall the drain pan and if required the lower front panel A CAUTION Ensure the drain pan s outer edge lower front panel is flush with the door panel i e not sticking out Failure to do so will damage the oven door resulting in a non warranty service call Step 12 Clean the Oven Exterior Wipe the oven exterior with a clean damp towel NM CAUTION DO NOT spray chemicals into any openings such as the louvers on the side panels or the rear vent catalyst housing Doing so can damage critical oven components resulting in a non warranty service call Step 13 Clean the Air Filter once per week Remove the air filter from the back panel Gently wash by hand in the sink or rinse with hot water A CAUTION DO NOT use a water jet Doing so will shorten the life of the filter Reinstall the air filter or replace it if large holes are present or if the mesh is becoming detached from the frame A CAUTION DO NOT operate the oven without the air filter in place Oven Controls and Cooking Figure 6 Oven Controls Oven Controls 1 Info Key When the oven is off or cooling down press to access the Info Mode see page 13 2 On Off Key Press to turn the oven on begin warmup or off cool down or to exit Info Mode page 13 3 Display The display shows information relevant to the current oven operation and or user options 4 Soft Keys There are ten soft keys
36. password 9 4 2 8 and press the Enter key From the Options screen the following oven options can be turned on or off Adjust Time screen see cooking step 6 page 11 for more details Cook More screen see cooking step 9 page 12 for more details Edit Mode see page 19 for more details Load Menu screen see page 15 for more details Demo Mode TurboChef use only DHCP TurboChef use only Oven Type Ensure this option is set to i5 Setting the Language NOTE Not available on some oven models From screen 2 of the INFO MODE Figure 16 page 13 press the L3 soft key to set a different language Each OVEN OPTIONS ADJ TIME DHCP OFF COOK MORE EDIT MODE LOAD MENU DEMO MODE OVEN TYPE I5 Figure 19 Options Screen time L3 is pressed a different language is selected in the following order English default Spanish French German Portuguese Italian Russian Greek Polish Setting the Date Time Having an accurate date and time is important for logging oven counts diagnostics and fault conditions should any occur The oven time and date are set at the time of manufacture however the operator may at some point be required to make an adjustment From screen 2 of the INFO MODE Figure 16 page 13 press the L4 soft key to access the Set Date Time screen Figure 20 To set the date and time 1 Use the L3 and R3 soft keys middle left and middle right to navigate between fields
37. per the instructions on page 24 8 Complete a MW leakage test pages 25 26 Adjusting the Oven Door Ensuring the oven door is parallel to the cavity frame is essential for safe and proper oven opera tion If the door is misaligned follow the proceed ing steps N CAUTION This procedure should be performed while oven is hot To avoid burns be careful when adjusting the oven door 1 Turn the oven on and warm it to its operating temperature If two temperatures are present warm the oven to the higher of the two temperatures 2 Remove the oven side panels 3 Remove the switch assemblies from each side 4 Loosen the four screws that hold the hinge assembly to the gusset plates Figure 31A 23 Slide the door in and out of the cavity making 10 Turn the oven on and enter TEST MODE page sure the gaps between the door and cavity face 16 for more details are the same distance on each side Figures 11 Observe the status indicators when opening 31B and 31C show misaligned doors and closing the door and confirm the sequence 6 Tighten the four screws and open close the PSM open MSP closed If necessary adjust door multiple times to confirm adjustment the switches page 24 and reconfirm the 7 Reinstall the door switches N With the door closed set the left side switch 12 Reinstall the side panels primary so the paddle is closed but not 13 Perform a MW Leak Test pages 25 26 pushing or bindin
38. test only When each test completes the oven will display PASS or FAIL AUTO TEST Sal DOORTEST BLOWER TEST MAG TEST HEATER TEST PSM t HBTM AGOW 1531 Figure 25 Self Test 18 TEST MODE Volt On This setting should not be changed in the field unless instructed by TurboChef Press the R2 soft key Figure 23 page 17 to enable disable the voltage from displaying in INFO MODE Typically this setting is disabled for ovens installed outside the United States Erase Default Oven Settings IN CAUTION Settings cannot be retrieved once an erase option is confirmed Press the R3 soft key Figure 23 page 17 to access the Erase screen From the Erase screen Figure 26 Press the L2 soft key to erase counters and fault logs Press the R2 soft key to erase counters fault logs menu settings temperature settings serial number date and time Doing so will also default all oven options page 14 for more detail to OFE with the exception of load menu ERASE SETTINGS ERASE COUNTERS COMPLETE ERASE AND FAULT LOGS Figure 26 Erase Settings 19 Overview of the Edit Mode The EDIT MODE serves three main purposes 1 To edit set temperatures 2 To edit names of food groups and recipes 3 To edit recipe settings To access the EDIT MODE 1 When the oven is off or cooling down press the Info key 2 Press the Down key to access screen 2 and select Set Options 3 Enter the pass
39. the oven is plugged in can result in serious injury or death To Replace This First Remove This item Part Number No Covers a Top Cover pe oe Items Obstructing Pece as Page A 5 Pagea Page A 9 Page A 11 RECESS Blower Motor Bottom 15 9042 Vv EMI Filter EMI Fil Brkt Blower Motor Top 15 9040 Vv EMI Filter EMI Fil Brkt Blower Wheel Bottom 103550 Vv Blower Motors Blower Wheel Top 103551 Vv Blower Motors Capacitor High Voltage 100232 v Capacitor Clamps Capacitor Clamp 100134 v Catalytic Converter 15 9066 v RTD and Heater Assy Control Board 15 3208 1 Vv Cooling Fan Exterior TC3 0433 Vv e Brkt Finger Cooling Fan Interior TC3 0433 Vv Cooling Fan Finger Guard 100086 Vv Filter Filter Bracket Cooling Fan Magnetron 100083 Vv Cooling Fan Magnetron Bracket 15 9263 Vv Diodes High Voltage 100481 v Display TFT 15 3207 v Display VFD OBSOLETE v Door Assembly 15 9308 Vv Door Gasket 15 9309 Vv Shunt Plate Door Handle 15 9253 Vv Door Skin Door Skin 15 9109 Vv Door Drain Pan OBSOLETE Vv Drain Pan Recessed 13 9252 Vv a Panel EMI Filter 100546 Y EMI Filter Bracket 15 9257 Vv Filter Air 15 9039 Vv Filter Bracket 15 9060 Vv Firmware Upgrade TFT Display 15 3206 v Firmware Upgrade VFD Display 15 3205 v Fuse F1 12 amp 100592 Vv Fuse F2
40. 100 138 500 142 290 146 060 149 820 153 580 157 310 161 040 164 760 168 460 172 160 175 840 gt 200 175 840 175 910 183 170 186 820 190 450 194 070 197 690 201 290 204 880 208 450 212 020 2 300 212 020 215 570 219 120 222 650 226 170 229 670 233 170 236 650 240 130 243 590 247 040 Figure 37 Temperature Resistance Relationship Class B Resistance 0 C 100 0 Alpha 0 003850 OVEN SYSTEMS Filtering System This section contains information about the following components Catalytic converter Drain pan Air Filter Vent catalyst Catalytic Converter The catalytic converter a VOC type catalyst is located behind the rear cook cavity wall and is responsible for cleaning the recirculating airflow The catalyst functions by substantially lowering the combustion temperature of grease entrained in the air path to approximately the same temperature of the airflow thus the grease burns and breaks down into CO and H O as it passes through the catalytic converter The catalyst will operate most efficiently at temperatures above 475 F 246 C The catalytic converter is self cleaning Under nor mal conditions it does not need to be cleaned and is not considered to be a component that requires scheduled maintenance Furthermore the catalyst material is very sensitive to certain chemical com pounds Irreversible damage can occur if the cata lyst is
41. 2 qty 2 9 Keypad 15 9247 None None 10 Power Supply 101211 Screw M3 x 8mm Sems PPHD Cres 103444 qty 3 11 Power Supply Bracket 15 9280 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 2 12 Relay K1 Filament 101273 ut Keps Hex 6 32 Ext Tooth Cres 102961 qty 2 13 Relay K2 Anode 101273 ut Keps Hex 6 32 Ext Tooth Cres 102961 qty 2 14 Relay K3 Monitor 101273 ut Keps Hex 6 32 Ext Tooth Cres 102961 qty 2 15 Relay K6 Voltage 101272 ut Keps Hex 6 32 Ext Tooth Cres 102961 qty 2 16 Relay K7 Mag Fan 101273 ut Keps Hex 6 32 Ext Tooth Cres 102961 qty 2 17 Relay K8 Stirrer 101273 ut Keps Hex 6 32 Ext Tooth Cres 102961 qty 2 18 Relay Bracket 15 9261 Screw 8 x 3 8 PH Mod Truss Cres 101682 qty 4 19 Relay Solid State K4 K5 Heaters 101286 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 2 NOTE Additional keypad detail on Figure A 6 page A 8 t NOTE i5 ovens with serial numbers after 00501 are not equipped with 12 amp F3 and F4 fuses instead they are equipped with a single 20 amp F3 fuse Older oven models may still be equipped with the 12 amp F3 and F4 fuses Replacing Items Removing Top Cover Required Figures A 4 A 5 A 6 A DANGER Before replacing any oven component ensure the oven is removed from any power source Replacing a component while the oven is plugged in can result in serious injury or death A CAUTION Before removing
42. 4 Vv Vv Door Switches Hinge Weldment Countrbince Bracket LHS 15 9326 Vv Vv Door Switches Hinge Weldment Countrbince Bracket RHS I5 9327 Vv Vv Door Switches Interlock Switch Monitor 102012 Vv Interlock Switch Primary 102012 Vv Interlock Switch Secondary 102012 Vv Jetplate Bottom 15 3200 Vv Rack Jetplate Top 15 3204 Vv Keypad 15 9247 Vv Lower Front Panel OBSOLETE Vv Drain Pan Lower Front Panel Covered 15 9282 Vv Magnetron Left NGC 3015 Vv Vv Magnetron Right NGC 3015 Vv Vv Motor Controller 100446 Vv Power Cord 15 9127 Vv Power Supply 101211 Vv Pwr Supply Brkt Power Supply Bracket 15 9280 Vv Rack 15 9168 Vv Rack Support 15 9165 Vv Rack Relay K1 Filament 101273 Vv Relay K2 Anode 101273 Vv Relay K3 Monitor 101273 Vv Relay K6 Voltage 101272 Vv Relay K7 Mag Fan 101273 Vv Relay K8 Stirrer 101273 Vv Relay Bracket 15 9261 Vv Relay Solid State K4 K5 Heaters 101286 Vv RTD Cook Cavity HHC 6517 Vv Shunt Plate Assembly 15 9307 Vv Door Smart Card USB Port CON 7005 Vv Control Board Speaker 104155 Vv Stirrer 15 9154 Vv Top Jetplate Stirrer Coupling Hub 104132 Vv Stirrer Motor Stirrer Coupling Spider Insert 104306 Vv Stirrer Motor Stirrer Motor 100884 Vv Stirrer Mtr Bracket Stirrer Motor Bracket 15 9075 Vv See page A 12 through A 13 for removing door hinge components magnetrons magnetron thermostats or waveguides
43. 81 3 PHASE VO COMMON 2 B PPPOA ONER CNRO RABE WHITE 2 our ENABLE 3 8 1 WHITE SPLICE 1 ORANGE HV TRANSFORMERS 0026 B7 TOP BLOWER GND J2 2 amp 4 BLACK GREEN 3 VOCOM 4 Br BLACK 100083 i B2 BOT BLOWER ENABLE J1 3 WHITE 4 STATUS OK 5 c 1 GRAY FA E fin ON B1 TOP BLOWER ENABLE J2 3 WHITE VO COMMON 6 END 4 E C22 K5 B2 SSR RELAY B 4 WHITE mI gt gt i C22 K5 B2 SSR RELAY B 4 WHITE Te ou i C21 K4 A2 SSR RELAY A 2 WHITE BLACK 1 is SOME 2 E BLACK Ne a EBEN LEGE eet aS 5 l C20 SPEAKER RED RED 2 240 vac ENABLE 3 B 2 WHITE K1 K2 K3 K7 K8 C19 24VDC INPUT V RED i 3 OUT OCOM 4 B 8 BLACK F RELAY DETAIL i C17 MAG OT 24VDC RED CEA 4 STATUS OK 5 B 10 BLUE E i 101273 i K7 1 0 COMMON _6 MAGNETRON OVERTEM C16 K7 B MAG FAN RELAY INPUT WHITE J4 E s m yee aoe i a C14 K2 B ANODE RELAY INPUT WHITE 11 102070 i ni A i C13 K1 B FILAMENT RELAY INPUT WHITE BMSC i T FE i i C12 MAG OT STATUS WHITE 100446 J3 MAG 1 MAG 2 l A a C11 K3 B MONITOR STATUS ORANGE Ss or gt c e clot A iB i C10 DS PRIMARY N O INPUT WHITE ac 2 180 240 2 BLUE 208 NCP NCf SY i gt C9 DS SECONDARY N O INPUT WHITE VACIN 3 BROWN o 240 3 i f f C8 24VDC RETURN BLACK zus Bin K6 RELAY i CONTROL BOARD C7 SPEAKER BLACK 61713 9 l1o Relay Test BLUE FILAMENT TRANSFORMERS gt i DETA
44. Cooking Done Step 9 Additional Cooking Options The Additional Cooking Options screen is turned off by default If you ADDITIONAL COOKING OPTIONS cook wore want the ability to cook a product a little beyond the standard cook time BROWN MORE you can enable this feature from the Options screen see page 14 COOK AND BROWN MORE SAVE ADJUSTED TIME If the Additional Cooking Options screen appears and the food product Figure 13 Additional Cooking requires more cooking Options Select cook more if the inside of the food item is undercooked Select brown more if the outside of the food item requires more browning or crispness Select cook and brown more if both the inside and outside of the food item are not done Select save adjusted time to save any change to the cook time made during Step 6 Note that this option is not available if Adjust Time is disabled Select exit to return to the food group selection screen Step 10 Cooling Down When finished cooking for the day press the On Off key to turn the POOLING DOWN oven off and begin cooling down PLEASE OPEN OVEN DOOR CC 288F During this step the oven blows cool air into the cook cavity to return it to approximately 150 F 66 C at which point the oven Figure 14 Cooling Down is safe to clean Info Mode Test Mode Edit Mode 13 Overview of the Info Mode The Info Mode serves four mai
45. IL C6 DS MONITOR amp SEC COMMON BLACK Pointe i 101272 f SEE CONTROL BOARD l C5 DS PRIMARY COMMON BLACK 112 4FT2 Qc1 QC2 l 2 8 i LISTING FOR PART C4 K6 B VOLTAGE RELAY INPUT WHITE 1 4 5 6 i i ee NUMBER C3 VOLT MODULE INPUT RED 1 Common Red 6 K7 Mag Fan White Done von 2 d IL IN er C1 TOP BLOWER STATUS OK 12 5 GRAY 2 K1 Filament White 7 K8 Stirrer White Cag V 24VDG BROWN E i A 8 f AO SaaS 2 3 K2 Mags White 8 K4 SSR White POWER N C 14 i 1 4 K3 Monitor Orange 9 K5 SSR White C8 Hv SUPPLY L BLUE i i O 321 O 5 K6 Volt White 10 Not Used G P EEEE J i o j J4 15 21 C 12 R B Sen 101211 fl a RTD gen 4 BLUE 2 2K 1 2W HX ELEMENTS 2 Cable Smart HHC 6517 Card Reader 6 l5 l4 Blower Motor 3 3000 WATT EACH 100182 Test Points VOLTAGE ee is 16 15 24 31230 MODULE A B SMART CN6 16 15 21 acio 100783 acg READER 1 Bottom Blower 0 10v Yellow A 17 C 13 CON 7005 a TFT DISPLAY 2 Bottom Blower Enable White B 2 B 17 RED m Fr 3 Top Status OK Gray C 1 al 00592 N NOTE VOLTAGE MODULE NOT PRESENT S 8 gl S Bl 2 3 EMLL 5 51 2 F3 20 AMPS ATMR 100599 A dc FOR INTERNATIONAL MARKETOVENS Sl El E CEN sd a E a 2 1 12 2 2 2 a HX 2 ALL FUSES ARE CLASS CC ESO O Sosa IN SN HF THE PD E SOE oie Be ne ne 3 4 5 6 7 22 21 1 NC 1 1 por 4 9 h0 Lt i 3 h 10 5 M ee ee es a E A A1 B1 12 11
46. Motor Bottom The bottom convection motor is a brushless AC switch reluctance type Its top speed is 7100 RPM at 1 HP The motor is controlled by a proprietary controller and spins clockwise The bottom blower motor can be tested in TEST MODE see page 16 Blower Motor Top The top convection motor is a brushless AC switch reluctance type Its top speed is 7100 RPM at 1 HP The motor is controlled by a proprietary controller and spins counterclockwise The top blower motor can be tested in TEST MODE see page 16 Blower Motor Controller BMSC The motor controller is proprietary and will only operate the convection motors described above It is controlled via 0 10 VDC speed command from the control board The blower motor controller can be tested in TEST MODE by testing the blower motors see page 16 For additional F1 fault trou bleshooting see page 37 21 Heater Element There are two main convection heaters each rated at 3000 watts at 208 VAC with a resistance of 14 4 ohms The convection heater is controlled by the K4 K5 solid state relay The heater element can be tested in TEST MODE see page 16 Older oven models use a finned heater while recently manufactured models use a helical heater If a finned heater fails the entire heater assembly must be replaced with the newer helical heater assembly i5 3214 since the helical heaters require a different mounting plate Jetplate Bottom The botto
47. PPHD SS 101661 qty 2 6 Cooling Fan Finger Guard 100086 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 2 7 CoolingFan Magnetron 100083 B Washer Lock 10 Int Tooth Cres B 102200 lay 3 8 Cooling Fan Magnetron Bracket 15 9263 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 4 9 Diode High Voltage 100481 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 2 10 Display TFT 15 3207 Nut Keps Hex 4 40 Ext Tooth 102960 qty 4 11 Motor Controller 100446 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 4 12 SmartCard UsB Port CON 7005 B Nut Keps Hex 440 Ext Tooth 6 102960 lay 4 13 Stirrer Coupling Hub qty 2 per oven 104132 Set Screw Provided None 14 Stirrer Coupling Spider Insert 104306 None None 15 Stirrer Motor 100884 Screw M4 x 0 7 x 8 PPHD Int Tooth SS 101672 qty 2 16 Stirrer Motor Bracket 15 9075 Screw M4 x 0 7 x 8 PPHD Int Tooth SS 101672 qty 2 17 Stirrer Shaft 15 9151 None None 18 Stirrer Shaft Support 15 9152 None None 19 Thermostat Cooling Fans 102086 Screw 6 x 1 2 PPHD Drill Point SS 101687 qty 2 20 Thermostat High Limit 102075 Screw M4 x 0 7 x 8 PPHD Int Tooth SS 101672 qty 2 21 Transformers Filament NGC 3061 1 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 4 22 Transformers High Voltage NGC 3062 1 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 4 Replacing Items Removing Left Side Cover Required Figures A 7 A 8 A DANGER Before replacing any oven co
48. Place hands into grips see Figure 2 and lift 4 Place the oven on the prepared surface or cart ensuring no edges are hanging off the sides 5 Install the oven rack 6 Plug in the oven NOTE The oven is primarily serviced through its top DO NOT install shelving directly over the unit The operator will be responsible for service charges incurred as a result of added time required to access the top of the oven NOILVTIVLSNI ANY SNOLLVDI4ID34S 4 SPECIFICATIONS AND INSTALLATION Installation Near Open Heat Source See Figure 3 page 5 When placing a TurboChef oven near an open heat source strictly adhere to the following If the oven is being placed near a grill or stove a divider must exist between the oven and the open heat source with a minimum of 6 152 mm between the oven and the divider If the oven is being placed near a fryer a divider must exist between the oven and fryer with a minimum of 12 305 mm between the oven and the divider The height of the divider must be greater than or equal to the height of the oven 24 3 or 618 mm Verify oven location has a minimum 16 406 mm clearance on top and minimum 2 51 mm of clearance on each side Optional Installation Items See Figure 4 page 5 TurboChef Oven Carts Part Number NGC 1217 1 Height 24 610 mm Width 27 8 706 mm Depth 26 625 676 mm Part Number NGC 1217 2 Height 17 3 439 mm Width 27 8
49. Verify the action of the switch actuators When the door closes do the actuators engage the switches NO f Adjust the counter balance assembly page 24 Is issue resolved oo A Refer to page 24 for proper adjustment steps The opening order must be P S M NO l door closed position the bracket so that the switch actuator is just engaging the switch levers Open and close the door Are door switches freely opening and closing a NO Is F4 MONITOR fault present in YES a Refer to trouble the fault log shooting procedures on page 40 YES Loosen the two switch bracket screws With the gt Replace the assembly counter balance Is the wiring from the door switches to con trol board OK NO wo Tighten the switch bracket screws Replace the door switch es YES y Correct wiring If wiring is damaged replace door switch es 43 DNILOOHSFIANOUL 44 TROUBLESHOOTING Troubleshooting No Display Screen is Blank YES Does the keypad beep when y a key is pressed Replace the fuses Is wiring from the control board to the display OK NO Correct wiring If ribbon cable is damaged replace the YES Y keypad Replace the power suppl
50. a smart card or USB Does a backup copy of the menu work H No backup copy NO TurboChef Is the connection from smart card reader to control board OK If the menu card was created by obtain a new menu card by contacting customer service at 800 90TURBO or 1 214 379 6000 NO i YES USB Device gt Is the file named correctly menudata bin and in the correct location TC_Menus NO YES Y Ensure the cable connecting the reader to the control board is securely attached and not damaged Name the file menudata bin and store it in a top level folder named TC Menus Y If the problem persists replace the control board Replace the card reader Is the USB device securely attached to the oven NO YES Verify the USB device is securely attached to the USB port on the oven Is the connection from USB port to control board OK Y YES Ensure the cable connecting the USB port to the control board is securely attached and not damaged Replace the card reader USB port If the prob lem persists replace the control board Troubleshooting Write Fail Message When Loading Menu p Smart Card Are you trying to write to a smart card or USB device Try writ
51. are controlled via the K1 relay Wiring the Filament Transformers A DANGER Never attempt to measure the secondary voltage values of the filament transformers when they are enabled Lethal voltage will be present The installation of filament transformers is straightforward Filament transformers are wired in phase and in line Refer to the schematic on page 49 detailing the proper wiring To verify correct wiring North America measure the voltages between terminals 1 amp 2 and 1 amp 3 on FT1 and FT2 The voltages must be 208 and 240 VAC respectively Continued on page 28 SWALSAS NJAO OVEN SYSTEMS NOTE The terminals with the orange dot or the orange wire always go to Terminal 3 on US models To verify correct wiring International measure the voltage between the taps on FT1 and FT2 The voltage must be 220 VAC Latin America 200 VAC Japan or 230 VAC International High Voltage Transformers High voltage transformers are a ferro resonant design which limits fault currents and minimizes magnetron power changes due to input voltage changes The high voltage transformer supplies the high voltage for the voltage doubler circuit They are controlled via the K2 relay Wiring the High Voltage Transformers N DANGER Never attempt to wire or measure the secondary voltage values of the high voltage transformers while they are enabled Lethal voltage will be present The proper reinstallation of a high volta
52. arge the high voltage capacitors 3 Disconnect all the wires in question going to the transformer 4 Use an ohmmeter to check the impedance of the primary and secondary winding Refer to the adjacent resistance table to determine if the transformer is OK If the resistance is different than the table indicates replace the transformer High Voltage Diodes The high voltage diode Figure 34 is assembled by connecting several 1000 1500 volt semi conductor diodes in a series to increase the reverse voltage capability In the circuit the high voltage diode conducts to prevent the filament voltage from becoming positive thus as the high voltage winding of the transformer goes to a peak of 2400 volts the high voltage capacitor is charged to 2400 volts gt Figure 34 High Voltage Diode High Voltage Transformers Primary Voltage Frequency Taps and Resistance Secondary Taps and Resistance NGC 3062 1 208 VAC 60 Hz 1 amp 2 0 819 1 001 Q 240 VAC 60 Hz 1 8z 3 0 972 1 188 Q 4 Ground 53 60 65 52 2 NGC 3062 2 230 VAC 50 Hz 1 amp 2 0 972 1 188 Q 3 Ground 57 52 70 30 Q NGC 3062 3 200 VAC 50 60 Hz 1 amp 2 0 784 0 958 Q 3 Ground 55 75 68 13 Q Filament Transformers Primary Voltage Frequency Taps and Resistance Secondary Taps and Resistance 15 70 19 18 Q NGC 3061 1 208 VAC 60 Hz 1 amp 2 4 5 very low r
53. atures use the highest temperature If a door adjustment is required refer to pages 22 and 23 for details 3 Ifan open door switch is not allowing the oven to preheat remove the side panels and loosen and move both the left and right door switch brackets to close the switches NOTE Step 3 is not a completed repair Proper switch operation must be confirmed before putting the oven into service continue to step 4 4 With the oven at operating temperature enter TEST MODE page 16 to view the status indicators of the primary secondary and monitor door switches 5 Adjust the position of the door switches brackets to ensure the proper sequence NOTE Opening the door must show the sequence as P S M Closing the door must show the opposite sequence M S P After final adjustments retighten the hex bolts and confirm the brackets are secure 6 Reinstall the side panels 7 Perform a MW leakage test page 25 Hinges and Counter Balance Assembly The door hinges and counter balance assembly ensure the door consistently opens and closes smoothly The counter balance assembly also allows the door to remain open at convenient positions i e partially open fully open Adjusting the Counter Balance Assembly Adjustments either increase or decrease the amount of counter pressure being applied to the door ZN WARNING This procedure requires work while the oven is hot To avoid burns be careful when adjusting the coun
54. breaker panel v If smoke is observed switch off or unplug the oven Keep the door closed to stifle any flames X DO NOT use the cook cavity for storage purposes X DO NOT overcook food Carefully attend to the oven if paper plastic or other combustible materials are placed inside the oven to facilitate cooking X DO NOT leave paper products cooking utensils or food in the cavity when not in use SAVE THESE INSTRUCTIONS SNOILINUYLSNI AL34VS SAFETY INSTRUCTIONS 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 oven is equipped with a cord that has a grounding wire with a grounding plug which must be plugged into an outlet that is properly installed and grounded Consult a qualified electrician or serviceman if uncertain about the ability to follow grounding instructions or if doubt exists as to whether the appliance is properly grounded x DO NOT use an extension cord If the power cord is too short have a qualified electrician or serviceman install an outlet near the appliance NM WARNING Improper grounding can result in risk of electric shock Power Cord Replacement If the power cord is damaged it must be replaced by the manufacturer its service agent or a similarly qualified person Precautions to be Observed Before and During Servicing to Avoid Possible Exposure to
55. ed continuously in all modes with special handling in the TEST MODE see page 16 If a fault is detected the control will terminate a cook cycle and display F1 Blower Upon turning on the oven the control will attempt to restart the motors If the restart of both motors is successful the fault code will be cleared from the display The fault is also cleared from the display at the onset of cooking or when a blower motor is tested in TEST MODE F2 Cook Temperature Low This fault is displayed if the cook cavity temperature is more than 84 F 47 C below the set temperature after five seconds into a cook cycle The fault is cleared from the display at the onset of cooking if the cook cavity temperature is within 84 F 47 C of the set temperature or when the heater is tested in TEST MODE see page 16 35 NOTE The F2 alarm can be turned off to prevent the cook cycle from being interrupted See page 14 for details F3 Magnetron Current Low This fault is displayed when the current transformer CT on the I O control board detects less than 10 amps The fault is monitored when the microwave is on during a cook cycle or in TEST MODE The fault is cleared from the display at the onset of a cook cycle if the CT detects 10 amps or when the magnetrons are successfully energized in TEST MODE F4 Door Monitor Defective This fault is displayed when the control detects that the monitor interlock switch unlatches b
56. efore the primary or secondary interlock switches In addition this fault will blow the F3 fuse F3 and F4 fuse for ovens equipped with an F4 fuse if the microwave high voltage system is energized when the fault occurs The fault is cleared from the display when the oven is powered off and then back on NOTE See the oven schematic page 49 The fault is monitored during a cook cycle and in TEST MODE when the microwave is on F5 Magnetron Over Temperature This fault is displayed when either magnetron thermostat reaches 212 F 100 C The thermostats will reset automatically and are wired in series The fault is cleared from the display at the onset of a cook cycle if the thermostat is closed or when the magnetrons are successfully tested in TEST MODE F6 Electrical Compartment Temperature High This fault is displayed when the EC thermocouple exceeds 158 F 70 C The EC temperature is monitored once per minute The fault is cleared from the display if on the next DNILOOHSFIANOUL check the EC thermocouple temperature is below the indicated limit TROUBLESHOOTING F7 RTD Open This fault is displayed when the control detects that the RTD is open for more than two contin uous minutes The display will show a reading of 999 F C indicating the RTD is open The fault is cleared when the control detects ohms in a proper range See Figure 37 page 33 for an ohm temperature chart F8 Heat Low Thi
57. eft 102070 Screw Sh Mtl Drill Point 6 32 x 3 8 PPHD Zinc 101684 qty 2 16 Thermostat Magnetron Right 102070 Screw Sh Mtl Drill Point 6 32 x 3 8 PPHD Zinc 101684 qty 2 17 Waveguide Left 15 3210 Nut Keps Hex 10 32 Ext Tooth Cres 102963 qty 9 18 Waveguide Right 15 3210 Nut Keps Hex 10 32 Ext Tooth Cres 102963 qty 9 19 Waveguide Gasket Left 15 9331 None None 20 Waveguide Gasket Right 15 9331 None None Figure A 10 Removing Opening Multiple Covers Required Figure A 11 Counter Balance Assembly Hinge and Switch Detail A 13 SININOdWO NAO DNIDV 1434 XIGNAddV For service or information WITHIN NORTH AMERICA CALL Customer Service at 800 90TURBO or OUTSIDE NORTH AMERICA CALL 1 214 379 6000 or Your Authorized Distributor Global Operations 4240 International Pkwy Suite 105 Carrollton Texas 75007 USA 1 214 379 6000 PHONE 41 214 379 6073 FAX Part Number i5 9231 Revision F April 2010 Country Code NA EU Customer Support 1 800 90TURBO 1 214 379 6000 turbochef com
58. en door and dispose of the hot water Oven Door Troubleshooting The following faults may occur in relation to the oven door F4 Monitor see page 40 The following issues may occur in relation to the oven door Cook Door Open message when door is closed see page 43 Microwave System Older i5 oven models employ two independent microwave systems left and right In the case of an over current situation relative to the left system the F3 fuse will blow In the case of an over current situation relative to the right system the F4 fuse will blow i5 ovens with serial numbers after 00501 are not equipped with an F4 fuse Both the left and right systems are wired to the F3 fuse In the case of an over current situation the F3 fuse will blow shut ting off both systems immediately This section contains information about the following components Capacitors Filament transformers High voltage Diodes High voltage Transformers Magnetrons Stirrer motor and assembly Waveguides This section also contains procedures for Testing a capacitor Wiring the filament transformers Testing a high voltage diode Wiring the high voltage transformers Testing a filament or high voltage transformer Testing a magnetron for an open shorted filament For information on accessing and removing parts see the Appendix Capacitors Capacitor rating is 0 91uF 2500 VDC for all 60 Hz installations
59. en is not always present THIS COULD RESULT IN VERY HOT LIQUIDS SUDDENLY BOILING OVER WHEN THE CONTAINER IS DISTURBED OR A UTENSIL IS INSERTED INTO THE LIQUID v Appliance is not to be used by children or persons with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction X DO NOT allow children to use this appliance Children should be supervised to ensure that they do not play with the appliance X DO NOT use corrosive chemicals or vapors in this appliance it is not designed for industrial or laboratory use X DO NOT operate this appliance if it has a damaged cord or plug is not working properly or has been damaged or dropped See Power Cord Replacement found on page ii DO NOT cover or block any openings on this appliance DO NOT store this appliance outdoors DO NOT use this product near water e g near a kitchen sink in a wet basement near a swimming pool DO NOT immerse cord or plug in water DO NOT let cord hang over the edge of table or counter DO NOT use a water jet for cleaning See the Maintenance section pages 7 8 for proper cleaning procedures x x x x x x Reducing Fire Risk v Remove wire twist ties from paper or plastic bags used to facilitate cooking in the oven v If materials inside the oven ignite keep the oven door closed turn the oven off and disconnect the power cord or shut off power at the fuse or circuit
60. ent is above 158 F 70 C an F6 EC TEMP fault will display The control board checks the temperature of the electrical compartment once every 60 seconds The electrical compartment thermocouple cannot be replaced on its own if it fails rather the control board must be replaced EMI Filter The EMI filter helps suppress the amount of RF interference emitted by the oven Fuses i5 ovens with serial numbers after 00501 are equipped with three fuses The F1 and F2 fuses are 12 amp ATMR The F3 fuse is 20 amp ATMR Older i5 oven models may be equipped with four 12 amp ATMR fuses The F1 fuse via blue wire or F2 fuse via brown wire is designed to blow in case of an over current situation relative to the following components BMSC motor controller Electrical compartment cooling fans Filament transformers Magnetron cooling fan Power supply Stirrer motor The F3 fuse is designed to blow in case of an over current situation relative to the microwave system magnetrons HV transformers diodes capacitors or a failure with the door interlock switches See page 24 for door switch adjustment details If the oven is equipped with an F4 fuse the F3 fuse controls the left microwave system while the F4 fuse controls the right microwave system SWALSAS NJAO OVEN SYSTEMS High Limit Thermostat The high limit thermostat is a 250 VAC 3 pole manual reset thermostat with a trip point of 572 F 300 C T
61. erased new menu settings must be either loaded via smart card USB drive page 15 or programmed manually pages 19 20 The oven will not cook unless settings are present Note that the steps below are not always sequential Typically multiple items will be cooked before cooling the oven Step 10 Step 1 Turn the Oven On When the oven is off Figure 7 the oven temperature has receded below TURBOCHEFIS 150 F 66 C but the display and keypad remain on OVEN OFF READY TO CLEAN Press the On Off key to turn the oven on Figure 7 Oven Off Step 2 Select Cook Temperature The oven can store either one or two cook temperatures To select a SELECT COOK TEMPERATURE Teve 5008 temperature press the adjacent soft key TEMP 2 350F Each temperature has 10 food groups assigned to it and each group consists of 10 food items 100 items per temperature The operator will Figure 8 Cook Temperature Select only be able to cook items associated with the selected temperature to cook other items on the menu a new temperature must be selected NOTE If both temperature settings are the same this screen will be bypassed and access to all 200 food items will be allowed Step 3 Warming Up During this step the oven warms to the selected or pre set temperature WARMING UP OVEN CC 244F OVEN SP 500F Figure 9 Warming Up Step 4 Soaking Once the oven temperature reaches the set point the oven will continue to wa
62. esistance if read 17 49 21 37 Q ing is open transformer has failed 240 VAC 60 Hz 1 amp 3 20 61 25 19 Q NGC 3061 2 230 VAC 50 Hz 1 amp 2 3 4 very low resistance if read 18 99 23 21 Q ing is open transformer has failed NGC 3061 3 200 VAC 50 60 Hz 1 amp 2 3 4 very low resistance if read ing is open transformer has failed High Voltage and Filament Transformer Resistance Table When the high voltage winding starts to go toward negative the high voltage diode becomes non 4 3 Fully discharge the capacitors Connect the voltage meter in series with diode conducting with the charged high voltage capacitor in series with the high voltage winding When the transformer gets to its negative peak of 2400 volts the voltage applied to the filament is 4500 volts The high voltage diodes are rated at 16 kVDC Testing a High Voltage Diode DA DANGER Never attempt to measure high voltage directly Death or serious injury could result 1 Disconnect the oven from the power source 2 Remove the top cover of the oven nN Using a multimeter set to DC voltage connect one meter lead to one side of a 9 volt battery and the other lead to one side of the diode Connect the other side of the 9 volt battery to the other side of the diode DC voltage should only be present on the meter in one direction Switch the meter leads on the diode which will cause the opposite reading to be visible
63. esult in a non warranty service call JDNVNALNIVW AIYA DAILY MAINTENANCE Step 7 Clean and Dry the Oven Door A CAUTION DO NOT spray cleaner directly onto the oven door gasket A or saturate it with water A CAUTION DO NOT scrub scrape or attempt to clean the oven door gasket A Doing so may cause the door to not close properly resulting in a non warranty service call Clean the oven door with oven cleaner and a nylon scrub pad Wipe the oven door with a damp towel Step 8 Rinse the Oven Interior A CAUTION DO NOT use a hose or water jet for cleaning Doing so can damage critical oven components resulting in a non warranty service call Rinse the oven interior with clean water Thoroughly dry the oven interior with a clean towel Step 9 Apply TurboChef Oven Guard Spray Oven Guard onto a clean towel Wipe the oven s interior walls and the inside of the oven door A CAUTION DO NOT apply Oven Guard to the oven door gasket Doing so may damage the gasket resulting in a non warranty service call Step 10 Reinstall Components Reinstall the lower air diverter Reinstall the lower jetplate Screw in the two thumb screws to lock the lower jetplate in place Reinstall the wire rack and close the oven door Step 11 Clean the Drain Pan If required remove the lower front panel Remove the drain pan entirely from the bottom of the oven Wipe down the inside of the area the drain
64. ew of Troubleshooting Fault Code Descriptions Fault Code Troubleshooting F1 Blower Running Status Bad Fault Code Troubleshooting F2 Cook Temperature Low Fault Code Troubleshooting F3 Magnetron Current Low Fault Code Troubleshooting F4 Door Monitor Defective Fault Code Troubleshooting F5 Magnetron Over Temperature Fault Code Troubleshooting F6 Electrical Compartment Temperature High Fault Code Troubleshooting F7 Open RTD Fault Code Troubleshooting F8 Heat Rise Low Fault Code Troubleshooting F9 Cook Cavity Temperature High Non Fault Code Troubleshooting No Keypad Input Non Fault Code Troubleshooting Door Open Message when Door is Closed Non Fault Code Troubleshooting No Display Screen is Blank Non Fault Code Troubleshooting Food Not Cooking Properly Non Fault Code Troubleshooting Read Fail Message when Loading a Menu Non Fault Code Troubleshooting Write Fail Message when Loading a Menu Non Fault Code Troubleshooting Defective Media Message When Oven is Plugged in or Restarted Oven Schematic Appendix Replacing Oven Components Comprehensive Table of Oven Components Replacing Items No Cover Removal Required Replacing Items Opening Top Cover Required Replacing Items Removing Top Cover Required Replacing Items Removing Left Side Cover Required Replacing Items Removing Right Side Cover Required Replacing Items Removing Opening Multiple Covers Required 35 35
65. g on itself 9 Set the right side switches secondary and monitor so they are completely closed but not pushing or binding on themselves Oven Frame Oven Frame Remove Remove Bolts Bolts ae Switches P di Oven Door Hinge Hinge Oven Door Figure 31A Properly Adjusted Door Side Views Remove Tap this gt D D Tap this Je switches gt C corner corner then tap here Figure 31B Door Misaligned 1 Side Views Figure 31C Door Misaligned 2 Side Views SWALSAS NJAO OVEN SYSTEMS Interlock Switches The primary secondary and monitor interlock switches engage and disengage in sequence to ensure a proper seal When the door is opened the switch sequence is P S M Subsequently the sequence is M S P when the door is closed Adjusting the Door Switches Proper door switch sequence is critical The safety interlock system is designed to disable the microwave circuit blow F3 fuse if the monitor door switch opens before the primary or secondary switches during microwave operation Verifying the door switchs equence is highly recommended when servicing an oven with a blown E3 fuse ZN WARNING This procedure requires work while the oven is hot To avoid burns be careful when adjusting the door switches Ensure the oven door is closed 2 Verify the oven door is adjusted properly and the oven is at operating temperature before attempting to adjust the door switches If the oven has multiple set temper
66. ge transformer is critical Upon removing a high voltage transformer make sure to note where each wire was installed Refer to the oven schematic page 49 detailing the proper wiring As shown in the schematic transformers are installed mirror opposite and wired 180 out of phase It is essential for longevity that the high voltage transformers remain 180 out of phase This can be checked by placing a volt meter across terminals T1 1 and T2 1 primary voltage With the microwave system energized the volt meter will read the incoming voltage different readings for different electrical installations If the meter reads 0 VAC the high voltage transformers are most likely wired in phase As a last check energize the microwave system and verify the voltages between the taps on each high voltage transformer The wiring issue must be corrected prior to return ing the oven to service as the voltages must be NORTH AMERICA 208 VAC between 1 amp 2 and 240 between 1 82 3 LATIN AMERICA 220 VAC JAPAN 200 VAC INTERNATIONAL 230 VAC NOTE The terminals with the orange dot orange wire always go to terminal 3 on USA models Testing a Filament or HV Transformer N DANGER Never attempt to measure the secondary voltage values of the transformers when they are connected to the magnetron circuit Lethal voltage will be present jean Disconnect the AC power source 2 Remove the top cover of the oven and disch
67. he oven menu to a USB drive 1 Insert the USB drive Figure 21 2 Press the L5 soft key Save to USB 3 Verify the oven beeps and reads FINISHED Updating the Oven Menu From screen 2 of the INFO MODE Figure 16 page 13 press the R1 soft key to access the Load Menu screen NOTE This feature can be turned on or off via the Options screen Figure 19 page 14 wa Card USB Port Smart Card Reader Slot Figure 21 Inserting Smart Card USB Device 13 To load a menu to the oven via smart card 1 Insert the smart card Figure 21 2 Press the L1 soft key Load from Card 3 Verify the oven beeps and reads FINISHED To load a menu via USB drive 1 Verify the menu on the USB drive is named MENU BIN 2 Verify the menu on the USB drive is in a folder named TC_MENUS This folder must not be a sub folder of any other folder 3 Insert the USB drive Figure 21 4 Press the L4 soft key Load from USB 5 Verify the oven beeps and reads FINISHED Updating the Oven Firmware Updating the oven firmware whenever TurboChef releases a new version will help ensure the oven main tains the best possible functionality Updates can be obtained from www turbochef com link at bottom of screen and loaded to smart cards via ChefComm Physical copies can also be ordered and shipped Contact TurboChef for more details A CAUTION Depending on the type of display i
68. he thermostat interrupts power to the main convection heater in the event of an abnormal condition Reset the high limit thermostat by pressing the reset button Figure 36 Reset Button Figure 36 High Limit Reset Button Keypad The keypad is a 7 x 10 matrix membrane switch For details on key functions see page 9 Magnetron Cooling Fans The magnetron cooling fans supply air to the magnetrons and are actuated by the K7 relay They operate at 208 240 VAC 60 Hz installations with voltage sensing 220 VAC 60 Hz installations with no voltage sensing 230 VAC 50 Hz installations 200 VAC Japan installations Magnetron Thermostats The magnetron thermostats are open on rise They are designed to open at 212 F 100 C which triggers an F5 fault NOTE The magnetron thermostats are wired in series If one opens the control will switch off both microwave systems until the open thermostat closes The thermostats are self resetting Power Supply The power supply outputs 24 VDC at 40 watts to the control board and relays Relay K1 Filament The K1 relay is a 240 VAC 30 amp double pole double throw 24 VDC relay coil It switches power to the magnetron filament transformers Relay K2 Anode The K2 relay is a 240 VAC 30 amp double pole double throw 24 VDC relay coil It switches power to the magnetron high voltage transformers
69. icrowave leakage If no leakage is found replace the control board Oven Schematic
70. ing to a new smart card Was the write successful NO f Is the connection from smart card reader to control board OK NO i USB Device Does the USB device contain a top level folder named TC_Menus NO Y YES On the USB device create a top level folder named TC_Menus Is the USB device securely attached to the oven Verify the USB device is securely attached to the connecting the reader to USB port on the oven Is the connection from USB port to control board OK Ensure the cable Ensure the cable YES the control board is securely attached and not damaged Y If the problem persists replace the control board Replace the card reader connecting the USB port to the control board is securely attached and not damaged YES USB port If the prob lem persists replace the control board Replace the card reader 47 DNILOOHSFIANOUL 48 TROUBLESHOOTING Troubleshooting Defective Media Message When Oven is Plugged in or Restarted Does the message prevent the oven a from reaching the Oven Off gt NO Cooling Down screen Unplug the oven and Operate the oven as then plug it back in YES you would normally Did this fix the problem NO Y Check for m
71. lectrical compartment cooling fan thermostat Electrical compartment thermocouple EMI Filter Fuses High limit thermostat Keypad Magnetron cooling fans Magnetron thermostats Power Supply Relay K1 Filament Relay K2 Anode Relay K3 Monitor Relay K6 Voltage Relay K7 Mag fan Relay K8 Stirrer RTD Smart card reader Solid state relay K4 K5 Heater Speaker USB port Voltage sensor Wire harness Control Board The control board controls each electrical compo nent of the oven See page 49 for a schematic 24 VDC can be measured at pin 2 of the J7 connector Display The TFT high resolution display is the primary user interface Older oven models may be equipped with a VFD display If the display needs to be replaced either VFD or TFT use the TFT display service kit i5 3207 Electrical Compartment Cooling Fans The cooling fans located in the rear of the oven are actuated by the cooling fan thermostat when the temperature of the electrical compartment reaches 120 F 49 C 31 Electrical Compartment Cooling Fan Thermostat The cooling fan thermostat actuates the rear cooling fans when the electrical compartment temperature reaches 120 F 49 C Electrical Compartment Thermocouple The electrical compartment thermocouple meas ures the temperature of the electrical compart ment If the temperature of the electrical compart m
72. ling see page 16 down or off screen press and hold the Info key for 5 seconds to reset the ER oven The fault should clear Ale NO Disconnect oven from este the power supply and then A YES reconnect The fault M S P should clear Troubleshooting F5 MAG TEMP Magnetron Over Temperature Is the airpath into the electri Verify wiring If neces saby teplice the cooling Open the top cover place the oven in cal compartment blocked or En NO TEST MODE and test the magnetrons YES gt clogged with debris Check see page 16 Are the magnetron the cooling fan finger guards cooling fans operating and filter on the back panel Verify wiring to magnetrons and verify Do the magnetrons pass testing in th a n NO 8 P 8 e magnetron thermostats are TEST MODE See page 16 SS not open Are wiring and Reno ne debris thermostats ok YES or reposition the Fault message oven away from l NO should disappear 4 Y obstruction Correct wiring replace the YES thermostats Replace the magnetron s and test again in TEST MODE Do the magnetrons pass testing Replace the control board Troubleshooting F6 EC TEMP Electrical Compartment Temperature High YES l Y Does the oven have room to
73. ling takes approximately 40 minutes DO NOT attempt to clean the oven until the oven displays Oven Off Step 2 Remove and Clean the Wire Rack A WARNING Be sure the oven interior is cool before you remove the wire rack Wash rinse sanitize and dry the wire rack Step 3 Remove and Clean the Lower Jetplate Unscrew the two thumb screws on the lower jetplate Lift the lower jetplate by gripping the thumb screws Remove the lower jetplate Wash rinse sanitize and dry the lower jetplate Step 4 Remove and Clean the Lower Air Diverter Remove the lower air diverter Wash rinse sanitize and dry the lower air diverter A WARNING DO NOT discard the lower air diverter The oven will not work without the lower air diverter installed Step 5 Wipe the Oven Interior Wipe any large particles from the oven interior with a damp towel Step 6 Clean the Oven Interior Spray oven cleaner onto the top bottom and sides of the oven interior A CAUTION DO NOT spray oven cleaner into the holes on the back oven wall Doing so can damage critical oven components resulting in a non warranty service call Allow Oven Cleaner to penetrate stains for five minutes Clean the oven interior with a nylon scrub pad A CAUTION DO NOT apply excessive pressure when wiping the top ceramic jetplate breakage will result in a non warranty service call A CAUTION DO NOT remove the top ceramic jetplate breakage will r
74. m jetplate channels air that is generated from the bottom blower motor into the cook cavity Jetplate Top The top jetplate channels air that is generated from the top blower motor This air passes through a stirrer before entering the cook cavity through the jetplate holes DA CAUTION The top jetplate is ceramic Be careful when removing or reinstalling it Stirrer Motor and Assembly The stirrer is responsible for evenly distributing hot air and microwave that are launched from the top of the oven into the cook cavity The stirrer is driven by a motor that remains on during a cook cycle or when the oven is in TEST MODE The stirrer motor turns off when the cook cavity temperature recedes below 150 F 66 C The stirrer motor can be tested in TEST MODE see page 16 N CAUTION Be careful to not allow debris into the waveguides when servicing the SWALSAS NJAO stirrer assembly OVEN SYSTEMS Convection System Troubleshooting The following faults may occur in relation to the convection system Fl Blower see page 37 F2 Low Temp see page 38 F6 EC Temp see page 41 F7 Thermo see page 41 F8 Heat Low see page 42 F9 CC Temp see page 42 The following cooking performance issues may occur in relation to the convection system Food not cooking properly see page 45 Oven Door This section contains information about the following components Oven door Interlock switche
75. mponent ensure the oven is removed from any power source Replacing a component while the oven is plugged in can result in serious injury or death A CAUTION Before removing installing any component make sure it is disconnected from the wire harness where applicable NM CAUTION Be careful to not tear the insulation when servicing components Always reset the insulation properly before reinstalling the side panel N NOTE Hardware listed is required for installing component to oven To remove the left side cover remove the screws securing the panel to the oven frame To re install the left side cover you may need to open the top cover see page A 5 De Item Description Item Part Number Hardware Description Hardware Part Number s 1 Blower Motor top 15 9040 Nut 1 4 20 Serr Hex Flange Plated 100906 qty 4 2 Blower Motor bottom 15 9042 Nut 1 4 20 Serr Hex Flange Plated 100906 qty 4 3 Blower Wheel top 103551 None None 4 Blower Wheel bottom 103550 None None 5 Cover Left Side 15 9301 Screw 8 Serr PHD Truss Black Oxide 101691 qty 5 6 EMI Filter 100546 Screw M5 x 8 PPHD Sems SS 101707 qty 4 7 EMI Filter Bracket 15 9257 Screw 10 32 x 3 4 lg PPH Sems Int Th 102937 qty 2 8 Heat Slinger 102708 None None 9 Helper Spring Interlock Switch i5 9397 None None 10 Interlock Switch Primary 102012 Screw 4 40 x 1 PPH Sems 102903 qty 2 11 Mounting Bracket Inte
76. n purposes 1 To display oven information 2 To provide access to Test Mode and additional diagnostic tools for service technicians To turn oven options and features on off 4 To update oven settings To access the Info Mode simply press the Info key when the oven is either off or cooling down To toggle between screens 1 and 2 press the Up or Down key From screen 1 of the Info Mode Figure 15 View the oven serial number View the oven software version View the menu part number and revision View the last temperature selected to cook View the electrical compartment temperature Scroll through counters total cook time magne tron time total oven on time and cook counter View the operating voltage North America models only Access the fault log Access service phone numbers S N i5 DXXXXXX COUNTS SCROLL SOFTWARE VERSION VAC 240 INFO 1 MENU P N AND REV FAULT LOGS SP 500F SERVICE NUMBERS EC TEMP 84F Figure 15 Info Mode Screen 1 TEST MODE LOAD MENU SET OPTIONS F2 ALARM ON SET LANGUAGE SET DATE TIME 05 01 09 11 14 28 Figure 16 Info Mode Screen 2 From screen 2 of the Info Mode Figure 16 Access Test Mode Access the Options screen Set the language not available on all models Set the date time Increase decrease the tone volume sound Access the Load Menu screen Turn the F2 Alarm on or off page 14 for details Viewing Cook Counte
77. ng to electro magnetic compatibility at the time of manufacture However some equipment with sensitivity to signals below these limits may experience interference If your equipment experiences interference Y Increase the physical separation between this oven and the sensitive equipment v If the sensitive device can be grounded do so following accepted grounding practices v If battery powered microphones are being affected ensure that the batteries are fully charged Y Keep sensitive equipment on separate electrical circuits if possible Y Route intercom wires microphone wires speaker cables etc away from the oven Specifications and Installation CTA aa E Figure 1 i5 Oven Dimensions Theory of Operation The i5 rapid cook oven combines precisely controlled impinged air and microwave energy to create higher heat transfer rates than conventional ovens Top launched microwave and impinged air are stirred to further ensure even heat distribution while impinged air enters the cavity from the top and bottom generated by dual independently controlled blower motors The combination of this technology with the size of the cook cavity allows for higher throughput than other batch ovens This manual includes instructions for servicing troubleshooting installing
78. nstalled VFD or TFT the oven will use a different firmware version The oven will be inoperable if the incorrect firmware is installed Ovens with a VFD display must use i5 3205 Ovens with a TFT display must use i5 3206 From the Oven Off screen 1 Insert the smart card see Figure 21 2 While the oven is either cooling down or off press and hold the Info key until the oven resets approximately 5 seconds 3 When the oven beeps one long high tone the load was successful Remove the card and if a second card was provided insert it 4 When the oven beeps one long high tone remove the second card to begin the reboot process 5 When the oven restarts and the display turns on the update is complete Remove the smart card 6 Verify the oven type is set to i5 Figure 19 NOTE If the update is unsuccessful the display will remain off and the oven will beep one long low tone If this occurs repeat the above procedure If the update fails multiple times contact TurboChef A CAUTION The oven will be inoperable if the firmware update is unsuccessful AGOW OJNI 16 TEST MODE Test Mode Testing Oven Parts From screen 2 of the INFO MODE Figure 16 page 13 press the L1 soft key to access TEST MODE Figure 22 When prompted enter the password 9 4 2 8 and press the Enter key From TEST MODE the oven s components can be tested independently or a comprehensive selective self test can be run Unle
79. or installing component to oven To remove the left side cover see page A 9 To remove the right side cover see page A 11 To open the top cover see page A 5 ee Item Description Item Part Number Hardware Description Hardware Part Number s 1 Hinge Bracket Slide LHS 15 9196 Nut Keps Hex 8 32 Ext Tooth Cres 102962 qty 4 2 Hinge Bracket Slide RHS 15 9195 Nut Keps Hex 8 32 Ext Tooth Cres 102962 qty 4 3 Hinge Cam Weldment LHS 15 9313 Washer Nylon Hingepin C0504 qty 1 4 Hinge Cam Weldment RHS 15 9314 Washer Nylon Hingepin C0504 qty 1 5 Hinge Guide Block Top 15 9394 Nut Keps Hex 8 32 Ext Tooth Cres 102962 qty 4 6 Hinge Guide Block Bottom 15 9393 None None 7 Hinge Gusset LHS 15 9178 Nut 1 4 20 Serr Hex Flange Plated Steel 100906 qty 2 8 Hinge Gusset RHS 15 9179 Nut 1 4 20 Serr Hex Flange Plated Steel 100906 qty 2 9 Hinge Module Base 15 9193 None None 10 Hinge Torsion Bar 15 9144 Spacer Adjustment Call TurboChef 11 Hinge Weldmt CtrbInce Brkt LHS 15 9326 Screw 10 32 x 3 8 lg PFLH 100 Deg SS 101401 qty 3 12 Hinge Weldmt Ctrbince Brkt RHS 15 9327 Screw 10 32 x 3 8 lg PFLH 100 Deg SS 101401 qty 3 13 Magnetron Left NGC 3015 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 4 14 Magnetron Right NGC 3015 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 4 15 Thermostat Magnetron L
80. osed Magnetron thermostat is closed The heaters are on Both blower motors are on Microwave is not being used Fault Log Press the L1 soft key Figure 22 to access the fault log This fault log is identical to the one accessible from INFO MODE screen 1 Figure 17 page 13 Turning Diagnostic Mode On Off Press the R2 soft key Figure 22 to place the oven in DIAGNOSTIC MODE When in DIAGNOSTIC MODE the oven displays additional cooking parameters during a cook cycle including Event currently being cooked Time left per event wave top air bottom air Status indicators Group and recipe name Actual cook cavity temperature Set point temperature For normal oven operation ensure DIAGNOSTIC MODE is turned off Manufacturing Mode Press the R3 soft key Figure 22 page 16 to place the oven in MANUFACTURING MODE Figure 23 When in MANUFACTURING MODE the following tests and settings can be accessed Microwave leakage test Microwave power test Burn in Serial number edit Temperature measurement F or C Self test Erase default oven settings Microwave Leakage Test Press the L1 soft key Figure 23 to initiate the microwave leakage test The oven will warm up to 500 F 260 C When warmup is complete insert the water load Follow the steps on pages 25 26 Microwave Power Test This test should only be performed by the manufacturer MANUFACTURING MODE
81. p 13 for detailed instructions Vent Catalyst In addition to the main catalytic converter the i5 oven contains an additional catalyst in the vent tube path This catalyst further assists in the breakdown of grease and particulate matter before the excess air enters the atmosphere Filtering System Troubleshooting The following issues may occur in relation to the filtering system F9 CC Temp if the catalyst is clogged with grease and debris see page 42 Fire in the cook cavity if catalytic converter is clogged due to oven not being cleaned regularly Electrical component failure if filter is not present or is clogged Undesirable flavor transfer Undesirable odor emissions Troubleshooting Overview of Troubleshooting This section contains information on the following Fault code descriptions Fault code troubleshooting Non fault code troubleshooting For information on accessing TEST MODE see page 16 For information and illustrations on replacing components see the appendix Fault Code Descriptions To view the fault log 1 When the oven is off or cooling down press the INFO key 2 Press the R3 soft key to view the fault counters 3 To view a detailed log of each fault occurrence press the soft key adjacent to the fault code F1 Blower Running Status Bad This fault is displayed when the motor controller indicates no running status The motors and motor controller are monitor
82. r HV TRANSFORMERS FILAMENT TRANSFORMERS CAPACITORS D c 10 ie o _ 60HZ NON JAPAN NGC 3062 1 60HZ NON JAPAN NGC 3061 1 60HZ NON JAPAN 0 91uf NGC 3020 QC5 B 16 50HZ NON JAPAN NGC 3062 2 50HZ NON JAPAN NGC 3061 2 50HZ ALL 50HZ OVENS NGC 3020 2 Wes e 1 Cs SH 1 aie a 50 60HZ JAPAN NGC 3062 3 50 60HZ JAPAN NGC 3061 3 60HZ JAPAN 0 85uf 100207 HE HHHH passen a gt NTE ONLY THE NGC 306 1 AND HENC 2067 HAVE 3 PARAS ALL OTHER TRANSFORMERS HAVE2 PAY APS O 1 MONITOR FAN1 mu E SWITCH Ne j COOLING COMPARTMENT fa a oa pol eo TC3 0433 BROWN e 1 M_a A I J11 i BIB TOP BLOWER 0 10VDE 21 RED i LS aj eA SPEAKER NOTE JUMPER ON CAPACITORS FOR 50HZ JUMPER 310 A17 BOT BLOWER O 10 VDC J1 1 YELLOW Teeconparv7no 1 104155 ACY B OPERATION ONLY ioka i A9 RTD 1 INPUT ORANGE INTERLOCK Po C16 1 BETWEEN TERMINALS 1 amp 3 f gt ip i A8 RTD 2INPUT ORANGE p ae ly el QC5 VAS LESS Sieg sue OD HL SS T1 D1 i A7 RTD 3INPUT RED i C 20 1 C1 100083 she y A5 VOLTAGE MODULE GND BLACK Ces CC7 2 K6 VOLTS 7 E A3 A4 car 1 240 ORANGE y MAG _ a eee E l l l CL ran Fd B17 RELAY COMMON 24VDC A RED po L ce ne Banner 02 E QC6 B16 K8 STIRRER RELAY INPUT WHITE J5 J2 MAG I o rl NGC 3015 B10 BOT BLOWER STATUS OK J1 5 BLUE gt 1 SAO MAC o 10v 1 at B RED CT Q 1h 41004
83. r Time Logs From the Info Mode Figure 15 press the R1 soft key Once to display total cook time Twice to display total magnetron time Three times to display total oven on time Four times to display the cook counter Viewing the Fault Log Figures 17 18 For more information on faults see pages 35 36 To zero the fault counters select Clear All From the Info Mode Figure 15 press the R3 soft key to view the fault log Figure 17 To view a detailed log of each fault occurrence Figure 18 press the soft key adjacent to the fault code FAULT LOG 8 F6 F1 BLOWER EC OT F2 LOW TEMP 0 F7 RTD OPEN 0 F3 MAG C LOW F8 HX RISE LOW 0 F4 MONITOR F9 CCOT 0 F5 MAG OT lt CLEAR ALL gt Figure 17 Fault Log F1 FAULT DETAIL 12 04 09 20 18 09 26 09 17 42 07 18 09 14 35 07 15 09 08 36 07 14 09 22 07 07 14 09 13 54 07 14 09 05 22 SCREEN 1 OF 13 M MORE W AGOW OHNI Figure 18 Fault Detail 14 INFO MODE Viewing the Service Numbers From the Info Mode Figure 15 page 13 press the R soft key to view technical support contact info Resetting the Oven Resetting the oven is one way to potentially clear an error message should one occur When the oven is cooling down or off press and hold the INFO key for 5 seconds Options Screen From screen 2 of the INFO MODE Figure 16 page 13 press the L2 soft key to access the Options screen Figure 19 When prompted enter the
84. r wire Confirm the F3 fuse is a Replace the F3 fuse and verify the operation of Y Replace K6 relay LN so lE located on the control O ne ie eee fuse Is it j YES the interlock switches board cn page 24 T YES YES NO i Y Run tet oak Are 10 amps present Is primary voltage present at the lese le during the F3 fault NO pe high voltage transformers page 28 3 alarm NEVER TEST SECONDARY repeats page 10 Replace the VOLTAGES If not clear faults YES control board Did fault repeat Replace affected YES NO YES components Replace the y NO Remove and inspect the magnetrons for discolored antennas or waveguide Reinstall all components and place the oven back in service NO high voltage transformer s Replace the contaminants Any defects found Energize the magnetron circuit from Test Mode page 16 and test for control voltage to the anode relay Is 24 VDC present on pins C 17 and C 14 on the control board f Replace the EE Energize the magnetron circuit from Test Mode page 16 and test for control voltage on the K2 anode relay Is 24VDC present on terminals A B NO Ja Inspect Replace wiring between C 17 C 14 of the control board and terminals A B of the K2 relay
85. rlock Switch 115 9272 Screw 10 32 x 3 4 lg PPH Sems Int Th 102937 qty 2 12 Power Cord 15 9127 None None 13 oltage Sensor 100783 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 1 NOTE For more interlock switch detail see Figure A 11 page A 13 SLNAINOdWOD N3AO NIDVIdd XIGNAddV A 10 APPENDIX REPLACING OVEN COMPONENTS ja ES x O gt E Ju be u 4 SSS lt 4 wg ES e 3 s Figure A 7 Removing Left Side Cover Required Figure A 8 Blower Motor Assembly Replacing Items Removing Right Side Cover Required Figure A 9 A DANGER Before replacing any oven component ensure the oven is removed from any power source Replacing a component while the oven is plugged in can result in serious injury or death A CAUTION Before removing installing any component make sure it is disconnected from the wire harness where applicable DA NOTE Hardware listed is required for installing component to oven To remove the right side cover 1 Remove the screws securing the panel to the oven frame 2 Remove the right side cover A Ao 35 ieee S A GIS A SB DBA e SBAA BO Figure A 9 Removing Right Side Cover Required gt 5 5 Figure ES nee m Item Description Item Part Number Hardware Description Hardware Part Number s Z Reference J 1 Catalytic Converter 15 9066 None
86. rm for eight minutes to ensure the cook cavity surfaces absorb enough heat so as to not affect cooking results This process is called soaking Step 5 Ready to Cook or Idle YA WARNING Inside of oven and oven door are hot 1 Place the food into the oven 2 Select a food group by pressing its adjacent soft key or press the Up or Down key for additional food groups if available 3 Select an item to cook by pressing its adjacent soft key Step 6 Adjusting the Time The Adjust Time option is turned off by default If you want the ability to modify the cook time before each cook cycle this feature can be ADJUSTTIME e turned on from the Options screen see page 14 START COOK 1 If the Adjust Time screen appears change the cook time if needed Figure 10 Adjust Time by using the number keys 2 Press Enter or bottom right soft key to confirm and begin cooking Step 7 Cooking NOTE To immediately terminate a cook cycle press the Back Stop key COOKING 01 17 NOTE If the oven door is opened during a cook cycle the cycle will GROUP 1 pause until the door is closed and Resume is selected Figure 11 Cooking 11 ONIMOOD ANY S1OY LNOD NIAO 12 OVEN CONTROLS AND COOKING Step 8 Remove Food from Oven IN WARNING Dish and inside of oven oven door are hot COOKING DONE PLEASE REMOVE FOOD FROM OVEN Open the oven door and check remove food Figure 12
87. s Hinges and counter balance assembly This section also contains procedures for Removing reinstalling the oven door Adjusting the oven door Adjusting the oven door switches Adjusting the counter balance assembly Measuring RF leakage for microwave safety For information on accessing and removing parts see the Appendix NOTE The proper fit and adjustment of the oven door is essential for safe and reliable oven operation The oven door assembly consists of a shunt plate skin and handle Each of these items can be purchased independently Removing Reinstalling the Oven Door To remove or reinstall the oven door follow the steps below For illustrations see page A 4 1 Ensure the oven has cooled to 150 F 66 C 2 Open the oven door to its full open position 3 Locate and remove the 8 32 screws 3 per side 4 Carefully remove the oven door by pulling the door away from the oven It will slide off the hinges and the hinge blocks will stay in place See Figure A 1 page A 4 5 To reinstall or fit a new door carefully slide it back over the hinge blocks and replace the 6 8 32 screws 3 each side 6 Verify that the door is parallel to the oven frame If it is not parallel adjust the door per the instructions below 7 From TEST MODE page 16 check the status indicators P S and M to verify the switches engage door closed and disengage door open properly If they do not adjust the switches
88. s fault displays during WARMING UP or TEST MODE if the cook cavity temperature fails to rise at least 14 F 7 C within a given 30 seconds F9 Cook Cavity Temperature High This fault will signal that the catalyst has flashed due to excessive grease The fault occurs when the RTD senses 650 F 343 C for more than 40 seconds but less than 2 minutes The fault will only appear in the fault log and will not terminate a cook cycle upon discovery F1 Blower Running Status Bad v v v v Page 37 F2 Cook Temperature Low v Page 38 F3 Magnetron Current Low v v Page 39 F4 Door Monitor Defective v v Page 40 F5 Magnetron Over Temperature v v Page 40 F6 EC Temperature High v v v v Page 41 F7 RTD Open v v v v Page 41 F8 Heat Low v Page 42 F9 Cook Cavity Temperature High v v Page 42 Figure 38 Fault Code Table Fault codes are listed in order of hierarchy For example if during cooking the oven experiences an F1 and F2 fault the oven will report only the F1 fault because the software will halt all actions upon discovering the F1 fault Fault codes F1 F5 and F7 will terminate a cook cycle upon discovery From TEST MODE you can run oven diagnostics and check fault counts To access TEST MODE or turn on Diagnostic mode see page 16 For illustrations on removing replacing oven components see the appendix at the end of this manual Fault Code Troubleshooting
89. see page 19 2 Select a block of food groups by pressing the corresponding right side soft key Figure 27 page 19 3 Select the group that contains the item s you want to edit Figure 28 Select an item to edit Figure 29 5 From the Recipe Edit screen Figure 30 edit the food group name Use the numeric keypad to change a character Press R1 soft key to advance to the next character Press L1 soft key to return to the previous character Press the R3 soft key to save changes 6 Edit the item name Press the Down key to move to the Ttem Name field Use the instructions provided in step 5 to edit the item name Chicken and Fowl Veggies amp Starch SP 500F Meat Seafood Sandwich Figure 28 Select Food Group FZN Wings 15 pc FZN Wings 25 pc EDIT Chicken and Fowl FZN Bnls Wings Breast 4 pc FZN Raw Tender X6 Figure 29 Select Recipe to Edit Appetizers Bake amp Casserole Pizza Blank Group Manual Cooking Duck Breast 2 pc Changing Recipe Settings To access the Recipe Edit screen follow the steps in the adjacent section titled Changing Food Group Item Name To change recipe settings 1 From the Recipe Edit screen Figure 30 press the Down key to move the cursor to the desired Event Setting field NOTE To help make navigation easier the currently selected field will be displayed in the top right corner of the display
90. sh etc IS Ensure that the correct amount is Contact Customer Service to obtain the correct menu and load it to the oven being cooked not more or less than the recipe specifies Ensure the food item is being properly stored prepared before cooking Is the oven rack posi tioned correctly upper vs lower position NO Y YES Y customer or contact Is the menu part number and revision correct Verify with TurboChef Customer Service Lo Place the oven rack in correct position Is the correct amount of food portion being cooked I gt Does the problem occur EVERY time the YES NO food item is cooked Y Y Replace the control Troubleshoot the YES Is the food item being prepared correctly and consistently For example bread cuts are straight and not V cuts meat is u sliced at correct thickness pizza dough is correct consistency etc Le NO 14 board fault s using the steps on pages 35 42 YES NO Y Are there any fault Le YES codes present See page 35 Ensure that the food item is properly prepared 45 DNILOOHSFIANOUL 46 TROUBLESHOOTING Troubleshooting Read Fail Message When Loading Menu Smart Card 3 IM device Did you use
91. ss otherwise specified idle airflow is set to 10 and the stirrer motor is turned on Top and Bottom Blower Each blower can be tested independently of the other at any speed setting While one blower is being tested the other will remain at 10 idle airflow Press the L2 soft key Figure 22 to increase top blower speed in 10 increments Press the L3 soft key Figure 22 to increase bottom blower speed in 10 increments Heaters Press and hold the L4 soft key Figure 22 to turn on the heaters They will turn off upon releasing the L4 soft key Magnetron Test Press and hold the L5 soft key Figure 22 to turn on the magnetrons To turn off the magnetrons simply let go of the L5 soft key Stirrer Press the R1 soft key Figure 22 to turn the stirrer on off TEST MODE FAULT LOG STIRRER ON TOP BLOWER 10 DIAGNOSTICS OFF BOTTOM BLOWER 20 MANUFACTURING HEATERS ON VOLTAGE 240 VAC MAG OFF CC 408F PSMt HBTM Figure 22 Test Mode Status Indicators Figure 22 The status indicators are located at the bot tom of the TEST MODE screen and consist of P Primary switch backlit open S Secondary switch backlit open M Monitor switch backlit open t Magnetron thermostat backlit open H Heaters backlit off B Bottom blower backlit off T Top blower backlit off W Microwave backlit off In Figure 22 All three door switches are engaged cl
92. ter balance assembly NOTE In Figure 32 some oven components have been removed for clarity The adjustment procedure must be performed with the counter balance and hinges installed to the oven chassis 1 Heat the oven to operating temperature 2 Ensure the door is adjusted properly and closed Refer to page 22 Adjusting the Oven Door Remove both side panels 4 Remove both left and right side door switch assemblies for access to the adjustment area 5 Remove the last gusset screws closest to the switch assemblies for tool access 6 Use adjustment tool P N i5 9387 to check the distance between the bracket and counter balance assembly see Figure 32 7 Insert the adjustment tool and use a 3 32 hex wrench to tighten the adjustment screw against the bracket so the tool cannot slide out 8 Loosen the screw just enough to allow the tool to be removed 9 Repeat steps 5 8 for the other side 10 Reinstall the gusset screws and tighten 11 Reinstall the door switch assemblies verifying the switches are in the closed position i e snug against the actuator 12 Warm up the oven allowing the additional 8 minute soak to achieve thermal equilibrium in the cook cavity 13 Adjust the door switches to ensure the proper opening and closing sequence details adjacent 14 Reinstall all components and side panels 15 Test for microwave leakage before returning the oven into service page 25 Bo 25
93. ventilate heat source clearances See page 1 for standard clearances 4 5 for open YES i Are both cooling fans rotating Is the oven in an area of moderate NO temperature 120 F 49 C or cooler Move oven to open area or remove items that are in close proximity Is the wire harness properly connected Check cooling fan thermostat and cooling fans H NO See page 49 for schematic YES j Check for obstructions in the airflow and remove them and clean the filter YES y Replace defective component Relocate oven to cooler area NO Correct wiring Troubleshooting F7 THERMO RTD Open Is the RTD open Using an Ohmmeter measure at the control board The Re YES 4 YES Is the RTD properly connected to the control board See page 49 for schematic NO gt Correct connection RTD should measure approximately 109 Ohms at 75 F 24 C See page 33 for complete ohm temperature chart gt Replace the RTD N Replace I O Control Board 41 DNILOOHSFIANOUL 42 TROUBLESHOOTING Troubleshooting F8 HEAT LOW i MEE YES Are both blower motors moving air NO
94. where applicable DA NOTE Hardware listed is required for installing component to oven ee Item Description Item Part Number Hardware Description Hardware Part Number s 1 Door Assembly 5 9308 Screw 8 32 x 3 8 PFH 100 Deg SS 102809 qty 6 2 Door Gasket 5 9309 None None 3 Door Handle 5 9253 Screw 1 4 20 x 25 lg Serrated Hex 102947 qty 4 4 Door Skin 5 9109 Screw 6 32 x 38 PFH 100 Deg SS 101430 qty 9 5 Drain Pan Recessed 3 9252 None None 6 Filter Air 5 9039 None None 7 ero oo Fest 8 Hand Grip 15 9256 Screw 8 X 1 2 Serrated PHTRH Black Oxide 101691 qty 2 9 Jetplate Bottom 15 3200 Screws and Mounting Clips Fast Lead 15 3201 SININOdWO NJAO DNIDV 1434 XIGNAddV A 4 APPENDIX REPLACING OVEN COMPONENTS a a Item Description Item Part Number Hardware Description Hardware Part Number s 10 Jetplate Top 15 3204 None None 11 Lower Front Panel Covered i5 9282 None None 12 Rack 15 9168 None None 13 Rack Support 15 9165 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 4 14 Shunt Plate Assembly 15 9307 Screw 6 32 x 38 PFH 100 Deg SS 101430 qty 9 5 Sie as ne heats 16 Vent Catalyst Foil Pack RWD 9191 None None 17 Vent Tube Cover 15 9209 Screw 6 x 1 2 PPHD Drill Point SS 101687 qty 2 18 Weldment Heat Chnl Vent Tube NGC 1397 Screw Sh Mtl 8 x 1 2 Serrated PHTRH 101688 qty 6 Figure A 1
95. word 9 4 2 8 and press ENTER 4 From the Set Options screen press the R3 soft key to turn Edit Mode on 5 Press the On Off key to exit the Options screen 6 Press the On Off key again to enter EDIT MODE Changing Set Temperatures The i5 oven can store two set temperatures Think of each temperature as a block of 10 food groups with 10 items each or 100 items per temperature If a menu was loaded via smart card or USB page 15 the temperatures are already set they need not be changed The set temperature should never be changed during normal operation Changing the set temperatures is not advised to compensate for over cooking or under cooking Rather consult your authorized distributor or TurboChef Customer Service if recipe settings are not cooking as desired To change a set temperature 1 Place the oven in EDIT MODE see adjacent 2 Select the temperature to change by pressing the adjacent soft key Figure 27 3 Using the number keys enter the new set temperature valid temperature range is 350 525 F 175 275 C 4 Press the Enter key to confirm the change or the Back Stop key to cancel L1 VALID RANGE BETWEEN 350 525F L2 EDIT TEMP 1 500F L3 LA EDIT TEMP 2 350F L5 EDIT TEMP 1 GROUPS EDIT TEMP 2 GROUPS Figure 27 Temperature Edit Screen AGOW 1103 20 EDIT MODE Changing Food Group ltem Name To change a food group or item name 1 Place the oven in EDIT MODE
96. y Is pin 1 on the J7 connector receiving 5 VDC see schematic page 49 Replace the control board YES Y Check wiring from the power supply to the Replace the display control board Correct wiring if necessary a NO a NO lt a NO Is the power supply receiving power YES Is the power supply output 24 VDC Is the control board receiving correct VDC Verify voltage on pin 2 of the J7 connector is 24 VDC see schematic page 49 l YES Verify 5 VDC is present on pin 1 of the J7 connector If not replace the control board Troubleshooting Food Not Cooking Properly Are there any fault codes present See page 35 NO YES Troubleshoot the YES 7 gt YES installed Is the lower air diverter NO i Install the lower air diverter and ensure it is in place after each cleaning Does the problem occur for all programmed recipes For example are all recipes undercooked overcooked etc fault s using the steps on pages 35 42 customer or contact Is the menu part number and revision correct Verify with TurboChef Customer Service NO YES roy NO NO Y i Is the food item in the correct starting state e g frozen fre
97. y until the defect is corrected In addition the SWALSAS NJAO Continued on page 26 26 OVEN SYSTEMS Figure 33 Survey Meter Placement 4 Place a water load into the cook cavity Water load must conform to the following specifications Volume 275 ml 15 ml Temperature 68 F 9 F 20 C 5 C Vessel Low form 600 ml beaker with an inside diameter of approximately 3 35 85 mm and made of Pyrex or equivalent 5 Close the oven door and press the Enter key The microwave system will turn on 6 Position the microwave survey meter where the door seals to the oven frame moving it while testing as shown in Figure 33 7 Measure microwave emission around the door moving the meter sensor at 0 5 inches 1 3 cm second As microwave leakage is observed while moving the sensor note any meter spike areas that come close to 5mW cm for later re measurement oo Replace the water load every 60 seconds until the test is completed and also after scanning the door 9 Close the oven door and return the meter probe to any meter spike areas and allow the probe to remain in the spike area for 17 seconds Note the highest reading obtained NOTE There may be several places on the door that require this procedure If so start out with a freshwater load each time a new area is measured or if measurement of an area takes longer than 60 seconds 10 After each test is complete open the ov

Service Manual 04/2010 (Rev. F)

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