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Turbo Chef Technologies NGC-1007 User's Manual

1. AdVaNOO3S ON HOLIMS m YOLINOW 27 ON 9 AHVINIHd ON ON PN ON 20 SSV10 SdWV 2124 7 A 2821 11 TS 3 3HIM o 3 ms HOLO3NNOO QUVI 1HVIAS E 917 088 Nua N E x18 9 35 VHd S m 5 uaria IN3 br AYA 4
2. 5 ON HOLIMS HO LINOW 9 ON EXAM AHVWWIHd 9 ON 9 99 SSV1O SdNV ZL II SSV1O ZL 24 A 50 88719 oz 3 1 O IR 9 S G INdNI SHIM HAND 8 amp 1 QHVO IHWNS FS Ol vaoz NO 9 ana N H O NMOHu8 i SZ 3SVHd 5 Id lt 4 136 MIN SYOOTY3LNI AL34VS m 5 HOLIMS 2 coals ON HO LINOW E 5 MOOTYS LNI 1 s on IETF zh 5 5 ON ON z ipn SINHO tL amp g Eus ao d SLLVM 000 93 ura
3. 02 9 NEN ca xm ANS 1H EDEA SWHO Frl SLIV 0006 19 Al AULLU amp N 3 JSIIENTITWAH jo c 3 m EB NLM JINGOW LDA AvZ 7 61 19 NLA WOO ISWE E A QAND 318vN3 6 ISWE B Wu ANODD Cm 3 S XE um NV DYW ZA TV nNVN d JENO NI WDIIUH 8 5 S 2 H lt AMD 114 OVW g8 TM 89 WAI 2848 E ino AGI O i AS DA3HI IYW Are 9 5 Nia B LINOWN Ave S e Abg IND Sd Are asf 40N 481 S IG E as gig i VT s LILY jt 919 NL Sd Ave Inanv 14 1 GIG kv Sd f HE LN a A TN Nigeg 505 NI WWNGOW 110 N3dsv t LJ LUNE AS OW amp SHL IYW OJOUNE SALYIS XH ern 1 11 3 OS ISAE 7 1 1 gt 254 NN g ON ABIV NOZ mm
4. Fan Blade Motor NGC 3007 38 Fan Magnetron Cooling 100083 20 Filter EMI 1Ph USA Europe Latin America Japan 100542 None Filter EMI 3Ph Europe Asia Pacific Korea Japan 100545 None Fuse F1 12 Amp 100592 38 Fuse F2 12 Amp 100592 38 Fuse F3 20 Amp 100599 20 Gasket Convection Heater NGC 1043 38 Gauge Door Switch Adjustment Tool NGC 1215 32 Grease Food Grade USDA H 1 NGC 3006 30 Guard TurboChef Oven Domestic 103181 None Guard TurboChef Oven International 103381 None Handle Door Standard 102750 35 Handle Door SBK NGC 1216 None Harness Line Voltage Europe Asia Pacific Japan NGC 1150 3 None Harness Line Voltage North America NGC 1150 1 None Harness Line Voltage UK Ireland Brazil NGC 1150 2 None Harness Low Voltage Old Switch Setup 100185 None Harness Low Voltage New Switch Setup NGC 1418 None Heater Element IR NGC 3003 39 Heater Convection NGC 3011 38 Hinge Left 102805 26 Hinge Right 102804 26 31 33 34 Insulation Door 1 NGC 1125 1 35 Insulation Door 2 NGC 1125 2 35 Insulator Adhesive NGC 1163 21 Keypad OUT NGC 1110 4 17 Keypad Standard NGC 1110 1 17 Keypad SBK NGC 1110 3 17 Keypad SWY NGC 1110 2 17 Label Caution Empty Cavity NGC 1165 35 Label Caution Hot NGC 1148 46 47 Label Precaution for Safe Use NGC 1138 35 Label Schem
5. BA NOONOD 13 9 Nowwoo t 5 e 02902 m INANI o 7 3 une on GNO Gas 5 00918 IE um IE z9r gs 8 8 I E x i Re e 2 5 2 a a 00018 c gt vL 2 g Ig ea wa 00088 SHOW SOVITOA ritea ilo Z Hird 8 110 ed OVAOvZ Y men zf 9er SINHO vv assy ge rye 2021 59 B 5 SLLVM 0006 07 PH gO toma Ten Hry Yl NOLLOS Ln ua TONMOOOTINGS dE 00 o 44 fa ov v3 4 joja ox 99 86 86 1 e orra Elle gt Jj SINHO FEL 15 252 uices 98 y e SLLVM 00 ZUN ay GEIGE IN3IN3 T3 XH i t mm p d ko o o n e 8 E ah Ww 8 sii ana 01 be be avna osna IM LA V 9 f1O AN 8 vM gt ASSVAVIdH iue sa au HH 19 80 X mw i BHM 8 8 LNO YI woLLog 8 Sy mI 5 d 6 oeza 4 LHM ZEHN 72172 NO 114 OVW 8 14 o ind ima 9 9 o 09r18 us s0 EX V sau 2162 05 18 4 Pc
6. 5 ON HOLIMS YOLINOW O9 ON ON 2 AHVINIHd ON ON 9 on 20 SSV 10 SANY ZI 14 a 00 SSV10 SdiNV 21 24 Q F 00 SSV10 SANV 02 INdNI SHIM NUS 4 wa N m T 2 2 GHW LEWIS N 5 S 3SVHd HALTS r Na 1 n 5 M3N S90 1H31NI AL3dVS QVI w m 5 m Humor IR 5 IH B 6 _HOLINOW n 219 o gt Nun 4 5 9 MOOTYALNI dS m i ON AHVINIHd 2 d m SWHO M 5 Ns ON d p SLIVA 000E Se z 03 a erregen e ON 490 1831NI ON oror IV m z AHV NOO3S 926 9 99 wus jY m ce 9 1 29090 gt 5 1 Ps a E res SE SE ESAE e 01 YK IE pee 9 9 RR Q Ov MS 52 eo RI N BE 23 anaon LION 2 Ten WOO gt 95 18 SINHO FEL e m E p a gayn oswa SLLYM 0066 I Len S STR Terme 6 06 QnoANOO ta vx WVHDVIC WC 8 y 62 62 Di avon zi 13838 ma em 2 82 1nOHWOLIOS 8 s ava 2122 OVW 9 1 ud 4
7. 3038 1176 1 1176 2 1176 3 1176 4 2011 8 1177 1148 102962 1187 1082 Stone Clear Glazed Label Schematic USA Label Schematic UK Ireland Label Schematic Eu Asia Pac 400VAC Label Schematic Eu Asia Pac 230 VAC Label Schematic Latin America Label Service Assistance Label Caution Hot Nut KEPS HEX 8 32 Ext Tooth CRES Pad Abrasive Non slip Cover Cooling Fan Comprehensive Part List COMPREHENSIVE PART LIST ITEM DESCRIPTION PART NUMBER FIGURE NUMBER PAGES 65 78 Actuator Door NGC 1076 2 29 35 Assembly Keypad Housing Cover Standard NGC 1054 1 46 Assembly Keypad Housing Cover SWY NGC 1054 2 46 Assembly Keypad Housing Cover SBK NGC 1054 3 47 Bearings Bronze 3 16 ID x 5 16 OD x 1 4 100059 30 Block Hinge NGC 1061 26 35 Block Sealing Blower Motor NGC 1024 38 Blower Motor NGC 1025 38 Bolt 1 4 20 x 1 00 102945 35 Bracket Stacking TC3 0323 None Cable Ribbon 26 Pin 100184 17 Cable Smart Card Reader 100182 17 Cable VF Display 3 Pin 100193 17 Cap Hole Door 101191 26 Capacitor HV Europe Asia Pacific NGC 3020 2 20 Capacitor HV Japan 100207 20 Capacitor HV USA Latin America S Korea NGC 3020 20 Cart TurboChef
8. OSrHH 5 8 o ON AHVQNOO3S ON a oe 2 u b ON 9 9 ON 7 90802 ON YOOTHALNI Z OVW 39 V L10 IH So 471 2 Ls AHVINIHd OVIN HOS 3OVLTOAIH HM bp S man e SION 28 ON HOLMS _ NOISN31 39V L10A HOIH 3009 80100 YOLINOW 2 2 GAY INdLNO TOHLNOO 3LIHM HM SASOTASLNFATZENS LNdNI SNLYLS SHFWHOJSNVHL AH 9NIMVHG NONNOI DQA ve 49V 18 39v 110 TONLNOD MO7 3009 JUIN OVA 072 SUFNYOISNVAL TIY NO dV L 062 HO L l Z 1 ovz 80z A INIT NMONA UR 072 802 A 3019 18 e HOLO3NNOO Nld 0 JO 3NI 3009 80102 H3MOd LNOHLIM QN V N3dO HOOQ NJAO SMOHS OILVIW3HOS I SALON GG 9ILVIN3H9S SN DON YQOODN C AUNDIA dNLas G10 SMOOTHALNI 134 5
9. K4 defective Unplug oven and replace K4 OK Unplug oven and verify all wiring Verify P1 voltage on board is 5 0VDC 0 02 see Figure 40 page 54 49 50 THE CONVECTION CIRCUIT ISSUE RESOLUTION Status Bad F1 Blower Running 1 Verify motor spins freely Motor seized Unplug oven and correct obstruction or replace motor Motor spins freely Verify motor windings see table below 2 Verify motor windings are OK Measure the resistance between windings and chassis Unplug oven and replace motor if resistances do not agree with the values in the table below If motor is OK proceed to step 3 below 3 Determine if status indicator A is highlighted backlit in TEST MODE A is highlighted backlit a Disconnect control wiring b Ground OR 9 to chassis to remove backlight on A c Keeping OR 9 grounded check terminals on the control wiring plug for 0 10 VDC control voltage reference drawing of QC3 plug on schematics pages 55 63 while incrementing blower speed in TEST MODE see BLOWER SPEED page 15 d If DC voltage is present throughout all speed settings in TEST MODE see BLOWER SPEED page 15 replace motor controller If not check harness and or replace I O board MOTOR WINDING RESISTANCES TABLE TO FROM DESCRIPTION EXPECTED RESISTANCE Black Red Winding A B 2 0 2 6 Ohms Black White Winding A C 2 0 2 6 Ohms
10. Screw 4 40 x 1 125 44 THE OVEN DOOR FIGURE 35 Oven Door Assembly OVEN DOOR ASSEMBLY See Figure 35 above For mis adjustments see Figures 27 and 28 on page 39 OVEN DOOR PARTS Figure 35 84 NGC 3067 Door NGC Generic NGC 3067 2 Door NGC SBK 85 NGC 3021 Kit Shunt Plate 86 NGC 1061 Hinge Block 87 102750 Handle Door Generic NGC 1216 Handle Door SBK 88 NGC 1076 2 Actuator Door 89 NGC 1132 Shim Door Latch 90 102945 Bolt 1 4 20 x 1 00 91 NGC 1138 92 102809 93 NGC 1165 94 NGC 1125 1 NGC 1125 2 95 NGC 1127 96 102748 97 101688 98 102698 99 NGC 1155 100 101293 101 1170 Label Precaution 8 32 x 3 8 CSK 100 Label Caution Empty Door Insulation 1 Door Insulation 2 Channel Door Handle Screw 8 32 x 3 8 Torx Security Screw 8 x 1 2 PTH Tape Aluminum Name Plate TurboChef Nut Push 1 8 Label Service Includes items 85 101 THE OVEN DOOR 45 E 9 9 4 5 15 s i ga E o 9 9 8 78 4 5 B us 49 2 ol2 ue e 10 13 14 oo 6 3 L E A 7 7 3 2 6 16 O SHUNT CAVITY PLATE SHUNT ASSY DOOR COVER
11. Hl WOLLOS 07 07 m IX 92 19 xnv o ed z E iN BE 5 93 2 STIANOIOWYSHL 0 vM T d A D r 021 8 uo ul E dee bel g ld fg HOC 1 62 n N In i 12 1 le Bee xd NR 5 55 DOS bis Komm 12770 ER m l e 2 em Le 9 oswa cee m rmm 2 a n SWHO FEL Lae z 9 Crm oglog Uno ANOO 9 un i zm mm rope m e f ove 19 40 Tam 72 72 QNO OVW 8 14 4 amp gc 9c 5205 60 Sc WOO oswa su wi me YT rau 2 2 1nO noro oswa 90 sna 62 c MS OWSHL 9 VW Atz Di d3H g UN 8 c lec WBS arz m gt Seal d Atz on 2 v 0278 02 02 NI Sd Atz 15 5 asn avoo SU ls Srau 6161 em m bo S Doe E z 881 5 2421 OVI LOVIN Ti cz sle B a NI Sd Ave CL Um BOIOJNNOO NI LIOA Sd Savi 200 100 Nid 9 JO ONIMVHQ ae Nadsv o a r SVN d NIMS OWB3H L OVW gt JOHOL NISNLVLS XH ara 6 id or e 6 00 sn v 9 9 oswa 7959908 p PPI a hy o alo alon d 8 8 5 l 5 k fk ru ON Z
12. 0 JO A INIT NMOYS QVAOEZ A INIT MOVIE TYYLIN 30718 18 39v L10A SNM 3002 40102 H3MOd LNOHLIM ONY N3dO HOOG SMOHS OI1VIN3HOS 71 SALON JILYWIHIS M3 29 opeurio QAODN FF INNA IA 5 010 SMOOTYALNI AL33VS
13. Diodes failed Unplug the oven and replace the diodes Diodes OK Unplug the oven and replace the defective magnetron Magnetron Circuit is Drawing Excessive Current Measure resistance of high voltage capacitor s Resistance should start out in the megohm range and continue to rise as the probes are held on the capacitor If the resistance is low less than the megohm range unplug the oven and replace the capacitor Visually check the associated high voltage transformer primary winding for signs of over heating winding is very dark and discolored If transformer primary winding looks bad replace it High Voltage and or Filament Transformer s Faulty Determine if the high voltage or filament transformer s is defective Use an ohm meter to measure the primary and secondary winding resistances Refer to the high voltage and filament transformer table on page 33 to determine if the transformer is OK If the resistance is different then the table indicates ensure the oven is unplugged and replace the transformer Wave Guide Covers Broken Replace the wave guide covers Follow the instructions on pages 29 30 and Figure 22 on page 29 Inspect the wave guides for debris If debris is pres ent replace the wave guide and the magnetron The Oven Door proper fit and adjustment of the oven door is essential for safe and reliable operation of the NGC Tornado oven The oven door provides th
14. USA Mexico Brazil volts peak to peak S Korea NGC 3062 2 HV Transformer 2 per oven 1 per kit Europe Asia Pacific Australia UK Ireland 2 The high voltage capacitor charges to 2400 volts on the positive going voltage via the high volt age diode s conduction NGC 3062 3 HV Transformer 2 per oven 1 3 The high voltage transformer plus the charged per kit Japan high voltage capacitor supply down to 4800 volts to the magnetron when the voltage goes 12 NGC 3020 High Voltage Capacitor 2 per oven per kit USA Mexico negative high voltage diode is back biased Brazil S Korea 4 The magnetron converts negative input voltage coment RE energy at 2450 NGC 3020 2 High Voltage Capacitor 2 per oven per kit Europe Asia Pacific Australia UK Ireland WARNING Do not attempt to measure Japan 50 Hz these voltages 100207 High Voltage Capacitor 2 per oven per kit Japan 60 Hz LULI DIT FIGURE 20 Microwave System Parts 13 100481 High Voltage Diode x2 14 Mag Fan Relay Generic NGC 3030 1 NGC 3030 4 Europe Asia Pacific Multiphase NGC 3030 7 North America Europe Single Phase NGC 3030 12 Brazil Single Phase
15. 35 MIN SMOOTHALNI AL34VS lz E 9 HOLIMS z 1 gt 2 S a 9 MOOTHALNI D qe SINHO 5 l L ON AYYNIHd 222 2 2 i ON ON B SLLVM 0006 SN 8 E 20 25 iru UNOLLOI 18 ON MOOTHALNI ON 0007 oo 28 dm AHVONOO3S 2 belee e vm SM i E ace Ox 69 Be gt sq3nooowWuaHl YSS Ov loe gg 5 ae E aC glag x Lg 295 V e geld E o Ov NES ee dad 2 2 SS T amp NLY z1ndOW LION Atz 12222 e amp SS A woo n osna 8 1H 2 79 3 w 2 no atawna oswa INvVHOVIG SINHO TET EHM s _ Yueuw e 06 Uno anoo C8 gt avo SLLVM 0066 25 8 e EET ZHM vem Igz 6z avaunvs ov zu JIN3IN3 13 XH 13S3H TV NVIA ma ma 82 820 1nou woos a ILO sua 10 2 72 8 1 Ee eem Su 92 82 WWoo 25 18 Gi 18 y LY 61 04 2 2 1 0 01 0 OSWa SH E 00 Xi amp a 6Z 6Z MS OWSHL OVW Avz gt Ns 2A LY 8 2122 Atz om m Tea 12 12 NLH H31NI d AZ 5112 vH Fave 02 8 NISd Ar2 olo n S ren M teat 66 Y 881 en 17 ZIZEL OVIN L OVI TONAN ezua ls N NISd AvZ gt le Sd
16. AND RESISTANCE SECONDARY TAPS AND RESISTANCE 15 70 19 18 Q NGC 3061 1 208 VAC 60 Hz 1 amp 2 4 5 very low resistance if read 17 49 21 37 0 ing is open transformer has failed 240 VAC 60 Hz 1 amp 3 20 61 25 19 0 NGC 3061 2 230 VAC 50 Hz 1 amp 2 3 4 very low resistance if read 18 99 23 21 0 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 34 THE MICROWAVE SYSTEM MICROWAVE SYSTEM TROUBLESHOOTING ISSUE RESOLUTION Magnetron WARNING Never test the secondary voltages Voltage on this side of the Troubleshooting circuit is lethal reaching up to 5000 volts Guidelines tests performed on the components are done with the oven unplugged and the capacitors discharged The capacitors in this oven utilize a device that will automatically discharge the voltage WARNING Always verify the capacitor is discharged before servicing the components Discharging can be done by unplugging the oven and then short across the red wire on each capacitor to the chassis with an insulated screwdriver F3 Magnetron Current Low 1 Remove the top and right side covers 2 Enter the test mode From the OVEN OFF mode simultaneously press BACK and ENTER keys enter the code 9 4 2 8 and press ENTER 3 Place amp meter on the brown US ovens or blue Internationa
17. Japan 50 Hz High Voltage Capacitor 2 per oven 1 per kit Japan 60 Hz High Voltage Diode x2 Mag Fan Relay Generic North America NGC 3030 4 Europe Asia Pacific MPh NGC 3030 7 Europe Single Phase NGC 3030 12 Brazil Single Phase Mag Fan Relay SWY NGC 3030 2 North America NGC 3030 6 Europe Brazil Single Phase NGC 3030 9 Europe Asia Pacific MPh 15 NGC 3061 1 NGC 3061 2 NGC 3061 3 16 17 18 100083 101273 101273 19 101273 20 100599 21 NGC 3015 22 NGC 3017 23 NGC 3016 CONTROL NO Filament Transformer 2 per oven 1 per kit USA 5 Korea Filament Transformer 2 per oven 1 per kit Europe Asia Pacific Latin America Filament Transformer 2 per oven 1 per kit Japan Mag Cooling Fan K3 Monitor Relay K2 High Voltage Relay K1 Filament Relay F3 Fuse 20 Amp Magnetron 2 per oven 1 per kit Wave Guide Rear Wave Guide Front See Comprehensive Part List page 79 TI North America Mag Fan Relay Additional 68 SERVICE PARTS AND ILLUSTRATIONS FIGURE 21 MICROWAVE SYSTEM PARTS Chapter 5 The Microwave System Page 27 Microwave System Parts 24 100186 25 NGC 3015 26 102070 27 NGC 1163
18. Key TEST NGC ROOX Until the display is CC 8PF in the Off State FAULTS STEST TEST NGC XXXXX IR500 F BPF IR 500 F IRBE ACCUM IRSI FIGURE 8 Accessing Test Mode To enter TEST MODE Figure 8 1 Press the BACK key until the display is in the OFF STATE 2 Simultaneously press BACK and ENTER keys 3 When prompted enter the access code 9 4 2 8 and press ENTER The TEST MODE displays the software version actu al cook chamber temperature and actual IR element temperature at the top of the screen The TEST MODE consists of 2 screens Figures 9 and 10 To display the second screen press either the UP or DOWN key To test a component or sub system press the corresponding soft key TEST FUNCTION OPTIONS Blower Speed Screen 1 The BLOWER key increments the blower motor speed in 10 increments When the speed is 100 the next press sets the speed to 0 NOTE If this function is being used to expedite cooling open the oven door to further expedite Faults Screen 1 Pressing the FAULTS soft key will display all the accumulated faults in the Fault Log Press 0 to zero the fault counter For more information see page 11 FIGURE 9 Test Mode Screen 1 FIGURE 10 Test Mode Screen 2 Self Test Function Screen 1 The STEST key initiates a self test to test all major components of the oven including door switches To run the
19. New Switch Setup Figure 35 Figure 37 Figure 38 Figure 39 Figure 46 Figure 47 Oven Door Assembly Convection Circuit Block Diagram Convection Circuit Assembly and Parts IR Element and Catalytic Converter Parts and Assembly Covers and Miscellaneous Parts Non SBK Ovens Covers and Miscellaneous Parts SBK Ovens Chapter Comprehensive Part List Comprehensive Part List 55 47 48 49 50 51 51 51 52 52 52 53 53 53 53 53 54 63 65 66 67 67 68 68 69 69 70 70 71 71 72 73 74 75 76 77 78 79 INTRODUCTION IMPORTANT SAFETY INSTRUCTIONS Strictly adhere to the following safety precautions to reduce the risk of 0 0 B DB Burns Electric shock Fire Injury Damage to oven or property near oven Exposure to excessive microwave energy GENERAL SAFETY INFORMATION m Read all instructions before using the appliance o Install or locate this appliance only in accordance with the provided installation instructions Some products such as whole eggs and sealed containers e g closed glass jars may explode and should not be heated in this oven Use this appliance only for its intended use as described in this manual o E E E El El E 8 This appliance should be serviced only by qualified service personnel Contact the nearest authorized service facility for examination repair or adjustment Keep cord away from heated surf
20. Smart Card Blank Smart Card Programmed Display Svc Kit includes Items 5 6 and 7 Spacer 1 2 Lg Aluminum ge 9 100193 100184 1110 1 1110 2 1110 3 1110 4 100506 10 100182 3 Pin Power Cable 26 Pin Ribbon Cable Keypad NGC Standard Keypad NGC SWY Keypad NGC SBK Keypad NGC OUT Smart Card Reader Smart Card Reader Cable Contact TurboChef 800 90TURBO or 1 214 379 6000 for more info part numbers THE CONTROL SYSTEM CONTROL SYSTEM TROUBLESHOOTING ISSUE RESOLUTION No Display Blank 3 The control DOES beep when any Key on the Keypad is pressed 1 Verify power 208 VAC or 240 VAC is going to the oven correctly If not correct the voltage supply 2 Control DOES NOT beep when any key on the keypad is pressed Check power going to the 24VDC power supply Supply must have 208 or 240 VAC across L and N terminals If there is no voltage replace 1 and F2 fuses If the voltage is OK verify output of power supply is 24 VDC If there is no output change the power supply If the power supply is 24 VDC see below Output is 24VDC Verify I O control board has 24 VDC by checking the voltage on the D6 diode striped end on the I O control board to chassis Reference page 54 for a schematic of the I O control board No voltage Check wires from power supply to I O control board Voltage is 24VDC b
21. TurboChef Service Manual FOR THE TURBOCHEF NGC TORNADO OVEN ETURBOCHES Accelerating the World of Cooking 800 90 TURBO Part Number NGC 1007 Revision D September 2007 For further information call 800 90TURBO 1 214 379 6000 ETURBOCHES Accelerating the World of Cooking IMPORTANT SAFETY INFORMATION PLEASE READ FIRST WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death Thoroughly read the installation operating and maintenance instructions before installing or servicing this equipment This product employs an exposed radiant heating element in the bottom of the cavity This element is HOT during operation and will remain at dangerous temperatures after the unit is switched off NEVER attempt to touch the element during operation while the oven is warm or while the oven is cooling down DO NOT store flammable vapors or liquids such as gasoline in the vicinity of this or any other appliance The information contained in this manual is important for the proper installation use and maintenance of this oven Adherence to these procedures and instructions will result in satisfactory baking results and help prevent maintenance Please read this manual carefully and retain it for future reference Errors descriptive typographic or pictorial are subject to correction Specifications are subject to change without notice Table of Conte
22. 9c 9c 2 62 2 oswa s 18 ina ia p 88 2 172 1 0 01 0 os na 9034 8 90 EZE ZIEZ NLY MS OWSHL OVW Av2 D v 2 22 Wes Ave 8 jerm 2 ESTE 12 12 NIHH3IN d Ave Ro ier twm iid ar m EZ 2 02 NiSd Avz 515 asn Lonoa EH er 9 ue 2 221 le o LOVIN SNB ale Sscag 91911 T HOLOSNNOO 0 2 21 T NIWNGOW LION SdVL 220 100 Nid 9 JO SNIMVHG gig vaesv T5 vd v4 E Too NMSOWHSHL E Nisnivis XH gem 2 f 15 2 0016 6 osnivis 6 oswa Esha 6 E m 2 m ON MEN c 8 8 NH3LN ON ABVONOO3S gt IN fa l e 5 9 s Tuo 2 14 NI H31NI ON AH VWIHd FT k a v Aziz Aziz tuo sug 9 9 NU31N ON vounon a ee SSHOLIMS 2 3 a we T E Ld ham 524 S OWYSHL 9 EIE 2 3 Em d uw o TH 2 d tno OW a z 19 nori II ast SGONV 24 OVI dias c cl A u Tez 77 ASSY AV HH LO cO gt Ex ET pum Bs N Os 5000 snana OdAre N KAA gd LJ zE EN 818 AHZN vA aaa m m gt snivis NIOVA Lz AAA p 8 m LL 5 2 OMEN qaas amp 2 et t 2 55 8 Z OVI 39V L1O IH ME SEEN A
23. Filament Transformers 101273 20 Relay K2 HV Transformers 101273 20 Relay K3 Monitor 101273 20 Relay K4 K5 Solid State Convection Heater IR Element NGC 3005 38 Relay K6 208 240 Transformer Taps USA only 101272 None Relay K7 Magnetron Fan DNK NGC 3030 11 None Relay K7 Magnetron Fan OXXO NGC 3030 5 None Relay K7 Magnetron Fan SBK USA NGC 3030 3 20 Relay K7 Magnetron Fan SBK Europe Asia Pacific MPh NGC 3030 15 20 Relay K7 Magnetron Fan SBK Europe SPh NGC 3030 13 20 Relay K7 Magnetron Fan SBK Indiana North Carolina NGC 3030 14 20 Relay K7 Magnetron Fan Standard USA NGC 3030 1 20 Relay K7 Magnetron Fan Standard Europe Asia Pacific MPh NGC 3030 4 20 Relay K7 Magnetron Fan Standard Europe SPh NGC 3030 7 20 Relay K7 Magnetron Fan Standard Latin America NGC 3030 12 20 Relay K7 Magnetron Fan SWY USA NGC 3030 2 20 Relay K7 Magnetron Fan SWY Europe Asia Pacific MPh NGC 3030 9 20 Relay K7 Magnetron Fan SWY Europe Latin America SPh NGC 3030 6 20 Relay K7 Magnetron Fan TESCO NGC 3030 10 None Relay K7 Magnetron Fan WAWA NGC 3030 8 None Ring E clip 101296 30 Ring Snap 101312 39 Screw 4 40 x 5 8 102902 31 Screw 4 40 x 3 4 101555 22 Screw 44 40 x 1 1 8 101558 33 34 Screw 4 40 x 1 1 4 101557 29 30 Screw 6 Sheet Metal 100684 21 Screw 8 Crescent TRHD Serrated Phillips 101688 35 38 39 46 Screw 8 Crescent TRHD Serrated Phillips Black Oxide 101691 47 Screw 8
24. Mag Fan Relay SWY NGC 3030 2 NGC 3030 6 Europe Brazil Single Phase NGC 3030 9 Europe Asia Pacific Multiphase North America Mag Fan Relay SBK NGC 3030 3 NGC 3030 13 Europe Brazil Single Phase North America NGC 3030 14 Indiana North Carolina NGC 3030 15 Europe Asia Pacific Multiphase Mag Fan Relay Additional 15 NGC 3061 1 Filament Transformer 2 per oven 1 per kit USA S Korea 15 16 17 18 19 20 THE MICROWAVE SYSTEM 27 FILAMENT AND HIGH VOLTAGE TERMINALS BMS lt lt ORG Y COOLING FINS BLK 4 D Sy ANTENNA Continued FIGURE 21 Microwave System Parts NGC 3061 2 Filament Transformer 2 per NGC 3061 3 100083 101273 101273 101273 100599 21 NGC 3015 22 NGC 3017 23 NGC 3016 24 100186 25 NGC 3015 26 102070 27 NGC 1163 28 100684 oven 1 per kit Europe Asia Pacific Australia UK Ireland Mexico Brazil Filament Transformer 2 per oven 1 per kit Japan Mag Cooling Fan K3 Monitor Relay K2 High Voltage Relay Filament Relay F3 Fuse 20 Amp Magnetron 2 per oven 1 per kit Wave Guide Rear Wave Guide Front Magnetron Wire Magnetron 2 per oven 1 per kit Magnetron Thermostat Insulator Adhesive Screw 6 Sheet Metal See Comprehensive Part List page 79 28 T
25. P 111 2 ND Zahlen 0 9 9 YILNI UND BDLINDA za gt m Ir 42 2 ziz E 8 S3HOLIAS b de TE WSIHL OVW aE Ze SEHR l E JUUNV 2 s 3 MB 5 1 2 0 11 ges 2 2548 LNO SN3WBCJSNVNI AH lt I WE G 8 YOLOANNOD Nid JO 9NIMNSC 1317449 ASMOd 1 11 ONY N3dl Z OWA 4 JAA FOVLIDA IH OWA aOd VLIDA IH CNDISNIL I9VL1DA 3003 30109 JlAve GIN M AdiNO TWALNOD HA NANI 501915 3 NYAD MD 2 IGA pa MOVIE IUBINUJ AU D 3002 au Id WAG 7 38 38 A INIT NADBH ai CWA0g2 A INIT SOWIE A ANIT ang 18 30V1TJA INID 3009 8009 ALLG HIJA SMOHS IILVWEHIS 5310 Service Parts and Illustrations FIGURE 7 NGC TORNADO CONTROL SYSTEM Chapter 4 The Control System Page 13 24VDC SERVICE PARTS AND ILLUSTRATIONS KI K2 K3 K6 RELAY RELAY RELAY RELAY US ONLY K5 K4 2AVDC 2AVDC 2AVDC 2AVDC 3 40 3 40 L 24VDC J jew POWER SUPPLY 25 e 88 MONITOR SWITCH gt NC
26. nal sheath temperature of the IR element Valid IR set points are between 500 F 260 C and 1150 F 621 C The display indicates 1999 F C if the thermocouple is open EC Thermocouple P N 700 1199 Type K Thermocouple Thermocouple measures the temperature of the electrical compartment If the temperature within the electrical compartment is above 158 F 70 C the control displays F6 EC TEMP The control board checks the EC tempera ture every 60 seconds CC Thermocouple Type K Thermocouple Thermocouple measures the temperature of the re circulating impingement airflow Valid CC set points vary depending on software If the display indicates 999 F C the ther mocouple is open BMSC Proprietary Brushless DC Motor Controller Designed solely to operate the blower motor VFD Display Vacuum Fluorescent Display Keypad 5x9 Matrix Membrane Switch Keypad is connected to the I O control board via 14 pin flat cable Voltage Sensor North America Only Proprietary device designed to measure incoming line voltage and switch between 208 and 240 VAC operation The device measures and allows the user to configure the oven only when the oven is first powered on Voltage sensor will default at 240 VAC TEST MODE The Test Mode allows the service technician to operate the oven s subsystems individually It also allows the operator to configure various presets THE CONTROL SYSTEM PRESS the Back
27. numbers If you are unsure which kit to order determine the software type before contacting Customer Service THE MICROWAVE SYSTEM 29 E il s Me gt FIGURE 22 Wave Guide Cover Wave Guide Removal and Replacement To determine software type 1 Make sure the oven is in the COOLING DOWN OVEN OFF mode 2 Simultaneously press the BACK and ENTER keys Enter code 9 4 2 8 W H A T and press ENTER 4 The top line on the screen will display the word TEST followed by the software type for example V2SWY or TRNADO Qo WAVE GUIDE COVER REPLACEMENT The wave guide covers keep moisture and debris out of the wave guides If contamination gets into the wave guides the life of the magnetrons may be shortened Be careful to not allow debris to enter the wave guides when replacing the covers To remove the wave guide covers reference Figure 22 and follow the steps below 1 Locate the fourteen 14 Z8 sheet metal screws securing the broken wave guide cover If the screw heads are dirty it will be necessary to clean the heads thoroughly N CAUTION Do not strip the screw heads 2 Remove the fourteen 14 8 screws The cover should come loose with gentle pressure DO NOT remove the two right and left most screws Item 30 These screws secure the wave guides to the oven floor Only remove them if the wave guide is also being serviced 3 Remove the
28. use the NGC 3016 kit If replacing the rear wave guide use the NGC 3017 kit 4 Remove the two 2 right and left most screws Item 30 that secure the wave guide to the oven floor 5 The wave guide should now be loose enough to easily slide out from the right side of the oven NOTE Be careful to not damage the insulation when removing the wave guide 6 Install the new wave guide using the mounting screws provided with the kit Item 34 if rear wave guide Item 37 if front CAUTION Do not pinch insulation between the wave guide and oven bottom 7 Reinstall the wave guide cover 8 Reinstall the side panel and apply power to the oven HIGH VOLTAGE AND FILAMENT TRANSFORMER REPLACEMENT Wiring the High Voltage Transformers The proper reinstallation of the high voltage and fil ament transformers is critical Upon removing a high voltage transformer make sure to note where each wire was installed Refer to the oven schemat ics pages 55 63 detailing the proper wiring Specifically T1 and T2 are located in the top right corner of the schematics As shown in the schematics transformers are installed mirror opposite and wired 180 out of phase It is essential for longevity that the high volt age transformers remain 180 out of phase This can be checked by placing a volt meter across terminals 1 1 and T2 1 With the Microwave System energized the volt meter will read the incoming voltage different readin
29. 28 100684 Magnetron Wire Magnetron Magnetron Thermostat Insulator Adhesive Screw 6 Sheet Metal FILAMENT AND HIGH VOLTAGE TERMINALS COOLING BLK 5 amp o Of FINS x L1 Lc FIGURE 22 WAVE GUIDE COVER WAVE GUIDE REMOVAL AND REPLACEMENT Chapter 5 The Microwave System Page 29 Wave Guide Wave Guide Cover Parts 29 NGC 3036 30 101666 31 101701 32 NGC 1047 Kit Wave Guide Cover Includes Item 31 and sealant Screws 48 32 x 1 2 Cap Screws 48 SST Support Frame QRA AA ES 33 102809 34 3017 35 3015 36 3015 37 3016 s 1 1 A 2 pA Tea Screws 8 32 x 3 8 CSK 100 Assy Wave Guide Rear Magnetron Rear Magnetron Front Assy Wave Guide Front FIGURE 24 amp 25 HIGH VOLTAGE DIODE AND MAGNETRON Chapter 5 The Microwave System Page 32 SERVICE PARTS AND ILLUSTRATIONS 69 FILAMENT AND HIGH VOLTAGE TERMINALS FIGURE 26 OVEN DOOR REMOVAL AND PARTS Chapter 6 The Oven Door Page 37 Cook Door Parts 38 102809 8 32 x 3 8 PFH CSK 39 NGC 3067 Assy Oven Door Traditional NGC 3067 2 Assy Oven Door SBK 40 NGC 1061 Hinge Block 41 102804 Right Hinge 4
30. 43 43 44 44 45 46 Chapter 7 Convection Circuit Convection Circuit Components Convection Circuit Blower Motor Parts Convection Circuit Troubleshooting Motor Winding Resistances Table Chapter 8 IR Element and Catalytic Converter Components IR Element and Catalyst Removal Removing the IR Element Removing amp Installing the Catalytic Converter Installing a New IR Element IR Element and Catalytic Converter Parts Chapter 9 Schematics and Schematic Components Schematic Parts Line Voltage Components Low Voltage Components Wire Harness Replacement P N s Control Board Item Identification and Test Point Locations Schematic Oven Schematics Chapter 10 I O Board Service Parts and Illustrations Figure 7 NGC Tornado Control System Figure 17 Figure 18 Figure 20 Figure 21 Figure 22 Control System Panel Enclosure and Parts Monitor Circuit Shown in Failsafe State Microwave System Parts Microwave System Parts Wave Guide Cover Wave Guide Removal and Replacement Figure 24 amp 25 High Voltage Diode and Magnetron Figure 26 Figure 29 Figure 30 Figure 31 Figure 32 Oven Door Removal and Parts Primary and Secondary Adjustment and Parts Old Switch Setup Door Switch Assembly and Parts Motor Switch Adjustment and Assembly Old Switch Setup Primary Interlock Adjustment and Parts New Switch Setup Figure 33 amp 34 Secondary and Monitor Adj and Assy
31. AMERICA Place the AC voltmeter across terminals 143 Press and hold the MGTRON soft key Voltage present should be 240 1096 INTERNATIONAL Place the AC voltmeter across terminals 142 Press and hold the MGTRON soft key Voltage present should be 230 1096 JAPAN Place the AC voltmeter across terminals 142 Press and hold the MGTRON soft key Voltage present should be 200 1096 If voltage is present on both high voltage transformers perform the compo nent troubleshooting steps in the previous pages of this section If voltage is not present check for 24VDC control voltage from I O board to the K2 relay Access voltage reading from the QC3 connection located at the bottom right side of the wiring harness When the MGTRON key is pressed and held 24VDC should be present on pins 1 5 Reference the schematics pages 55 63 for physical location of pins on QC3 connector If voltage is present at the connector inspect the K2 relay and the wiring Unplug the oven and replace relay if necessary If voltage is not present at connector check wiring connections at the con trol board on the 40 pin connector Also check the wiring between the two connectors Unplug the oven and replace control board if necessary F3 Fuse Blown Replace the F3 fuse and determine why F3 fuse opened Generally the F3 fuse opens for one of three reasons a HV transformer primary winding shorted Unplug the oven and replace the HV tran
32. BOTTOM IR AND CCV Bottom Infrared Element Catalytic Converter 7 THEORY OF OPERATION GLOSSARY OF COMMON OPERATING TERMS Off State All the oven s control systems are off and the cook cavity temperature is below 150 F 66 C Cool Down A subset of the OFF STATE During COOL DOWN the oven will circulate the main convection blower until the cook cavity temperature is below 150 F 66 C Ready State The oven has successfully warmed to the predefined set temperature At this point the oven control is ready to receive cook commands via the keypad The oven will maintain the set temperature in the READY STATE Set Temperature Cook Cavity CCSP Predefined temperature of the cook cavity at which the oven cooks Set Temperature IR Element IRSP and IRSI IRSP is the set temperature of the IR element during a given cook cycle Settings are determined on a per recipe basis IRSI is the set temperature of the IR element during the READY STATE or idle IRSI setting can be adjusted in the TEST MODE page 16 Actual Temperature Cook Cavity TCC The actual temperature registered by the cook cavity thermocouple Actual Temperature IR Element TIR The actual temperature registered by the IR element Edit Mode Enables the user to change recipe and CCSP IRSP temperature settings Warm Up The mode in which the oven warms itself to the set temperature Soak The mode in which the oven temperature has reached the CCSP
33. Blower motor is moving air Verify high limit thermostat is not tripped See the high limit thermostat information below High Limit Thermostat Thermostat tripped Reset and determine why the thermostat tripped See Figure 38 Item 114 Look for excess build up of grease inside the oven or any other source for a fire Thermostat is not tripped Check main convection heater 1 Convection heater is defective Unplug oven and replace the convection heater and verify the K4 SSR Figure 37 is not shorted across output 2 Convection heater OK Check the K4 SSR K4 defective Unplug oven and replace K4 OK Unplug oven and verify all wiring Verify P1 voltage on board is 5 0VDC 0 02 see Figure 40 page 54 F2 Cook Temperature Low 1 Verify Cook Door Operation Cook Door Open Message Verify which switch is not actuating and readjust See pages 38 43 Cook Door OK Verify high limit thermostat is not tripped See the high limit thermostat below High Limit Thermostat o Thermostat tripped Reset and determine why the thermostat tripped See Figure 38 Item 114 Look for excess build up of grease inside the oven or any other source for a fire Thermostat is not tripped Check main convection heater 1 Convection heater is defective Unplug oven and replace the convection heater and verify the K4 SSR Figure 37 is not shorted across output 2 Convection heater OK Check the K4 SSR
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35. South Korea NGC KW 3 phase Voltage 400 VAC 60 Hz Wye 5 wire 3L N Ground Circuit Breaker Type D min 20 Amps POWER INPUT Heaters Input Power NA 5990 6675 watts Heaters Input Power Intl 6300 watts Microwave Input Power 3500 watts Maximum Independent Input Power DELIVERY AND PRODUCT PLACEMENT Remove oven from carton Immediately note any damage and contact shipping company within 24 hours in order to file a claim TurboChef is not responsible if the product is damaged in shipment Remove all literature and accessories from the carton NOTE Thoroughly check the carton before discarding WARNING Oven weight is approx 190 lbs 86 kg Two or more persons are required to lift it Lifting and Placing the Oven Position one or more persons on either side of the oven and lift from the bottom Never lift the oven from the front and rear Place the oven on a counter top surface at least 28 711 mm deep and capable of supporting 200 Ibs 91 kg Once properly positioned on the counter plug the oven into wall mounted electrical receptacle See page ii for grounding instructions AN WARNING Never lift the oven by its door handle Physical damage to the oven and or personal injury may result The operator must ensure that the oven is properly placed on the countertop at all times TurboChef will not recognize a fallen oven as a warrantable claim and is not liable for any injuries that may result B
36. Tightening Sequence Tightening Sequence FIGURE 36 Oven Door Assembly Tightening Specs Critical Adjustment Notes Figure 35 SCREW TORQUE CHART 1 Orient with the gasket seam at the bottom of Refer to Figures 35 36 the door assembly Gasket should be straight with no twists or pinching PART TORQUE VALUE 2 Attach insulation Item 94 to the inside of the door cover using aluminum tape Item 98 90 Bolt 1 4 20 x 1 00 30 lal bs 9 04 Nm DO NOT block openings at bottom f 85 Nut Keps 8 32 21 In Lbs 3 Item 94 insulation not shown for clarity Assembled by 2 37 Nm 4 Door should be flat without twisting or warpage after tightening all hardware 96 Screw 8 32 x 3 8 21 In Lbs Torx Security 2 37 Nm 5 Refer to the chart to the right for torque specs Refer to Figure 36 above for tightening 97 Screw 8 x 1 2 PTH 21 In Lbs sequences 2 37 Nm 6 Attach Item 99 with adhesive backing using the two locating holes on the front cover 46 THE OVEN DOOR INTERLOCK SWITCH TROUBLESHOOTING ISSUE RESOLUTION Cook Door Open Message Determine which interlock switch is open Access TEST MODE to view interlock switch status Primary and or secondary interlock is open old switch setup SM Primary interlock is open new switch setup Verify action of the latch assembly and oven door When the door closes the actuator should freely clear the slot
37. be plugged into an outlet that is properly installed and grounded Consult a qualified electrician or serviceman if uncertain about the ability to follow ground ing instructions or if doubt exists as to whether the appliance is properly grounded DO NOT use an extension cord If the power cord is too short have a qualified electrician or service man install an outlet near the appliance N WARNING Improper grounding can result in risk of electric shock POWER CORD REPLACEMENT If the power cord is damaged it must be replaced by the manufacturer its service agent or a similarly quali fied person RF INTERFERENCE CONSIDERATIONS The NGC Tornado oven generates radio frequency signals This device has been tested and was determined to be in compliance with applicable portions of FCC part 18 requirements and to the protection require ments of Council Directive 89 336 EEC on the approximation of the laws of the Member States relating to electromagnetic compatibility at the time of manufacture However some equipment with sensitivity to signals below these limits may experience interference If your equipment experiences interference Increase the physical separation between this oven and the sensitive equipment If the sensitive device can be grounded do so following accepted grounding practices If battery powered microphones are being affected ensure that the batteries are fully charged Keep sensitive equipment on separate electri
38. cavity Install the oven rack cooking surface Stacking 1 Ensure the surface that will hold the stacked ovens can support at least 400 lbs 181 kg 2 Allow ovens adequate time to cool and unplug them 3 If you are stacking ovens on a TurboChef oven cart 24 NGC 1217 1 18 NGC 1217 2 make sure that the bottom oven is bolted to the cart and the wheels are locked 4 Attach the stacking bracket P N TC3 0323 to the back of the bottom oven a Remove the two screws that hold the top panel to the back of the oven see bottom arrows on Figure 4 b Align the holes on the stacking bracket with the holes on the oven and reinstall the screws Remove the legs of the oven that will be placed on top This requires two or more persons at least one person to lift and one to unscrew the legs 6 Remove the screws from the oven that will be placed on top see top arrows on Figure 4 7 Place this oven on top of the other the one to which the stacking bracket is attached WARNING Do not attempt to lift the oven with fewer than 2 people A WARNING Do not lift oven from front and back 8 Align the holes on the bracket with the holes on the top oven and reinstall the screws WARNING Do not stack ovens over two high Programming The oven is preprogrammed and ready to oper ate out of the box Initial Power up To turn on the oven press the bottom right soft key next to the words OVEN ON on the display
39. element protrudes through the cook cavity walls and remove the snap rings Item 116 using snap ring pliers Retain snap rings Item 116 and washers Item 117 Figure 41 4 Locate and remove the microwave shield Item 119 by removing the four 4 48 x 1 2 sheet metal screws Item 120 NOTE Some models do not contain item 119 5 Squeeze the IR element together inside the cook cavity and pull the IR element from the oven 52 FIGURE 39 Element and Catalytic Converter Assembly IR ELEMENT AND CATALYTIC CONVERTER Removing and Installing the Catalytic Converter 1 Unplug the oven 2 Remove the IR element See above procedure 3 Once the IR element has been removed remove the catalytic converter clip Item 121 to access the catalytic converter Figure 39 NOTE It may be necessary to remove the blower motor assembly see page 48 to get access to the top of the catalytic converter This will allow the catalytic converter to be pushed down out of the housing Figure 39 4 Remove the catalytic converter Item 122 Inspect the condition of the catalytic converter and either clean it or install a new one CAUTION Clean catalytic converter using only TurboChef cleaner P N 103180 USA 103380 Intl Use of other chemicals will irreparably damage catalyst Installing a New IR Element 1 Unplug the oven 2 Gently squeeze the new IR element together in order to get the terminals and lead wi
40. high volt age capacitor in series with the high voltage winding When the transformer gets to its negative peak of 2400 VPK the voltage applied to the filament is negative 4500 volts WARNING Never attempt to measure high voltage directly How to Check a Diode 1 Disconnect the oven from the power source 2 Fully discharge the capacitors 3 Connect the voltage meter in series with the diode 4 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 5 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 6 Switch the meter leads on the diode which will cause the opposite reading to be visible Depending on the voltage of the battery voltage between 5 7 VDC should be present in only one direction and 0 0 1 VDC in the other direction How to Check Capacitor 1 Disconnect the oven from the power source Fully discharge the capacitor 2 3 Isolate the capacitor from the circuit 4 Connect the ohmmeter between the capacitor terminals The ohmmeter should momentarily THE MICROWAVE SYSTEM 3 An ohmmeter connected between the filament indicate a low impedance and then slowly return to infinite resistance 6 Check each terminal to case Infinite resistance open should be indicated Reverse the ohmmeter leads and repeat
41. imperative to understand how the Monitor Circuit operates The Monitor Circuit is a failsafe circuit designed to protect the operator if both the primary and secondary inter lock switches fail to operate normally The Monitor Circuit consists of the primary and secondary interlock switch monitor safety switch monitor relay and the F3 fuse When the oven door closes during normal operation the monitor secondary and primary switches close in the order listed above When all switches are closed the Microwave System is allowed to operate THE MICROWAVE SYSTEM If during normal operation any of the interlock switches open such as when the oven door opens the control will turn off the microwave If the monitor switch opens before the primary or sec ondary switches abnormal operation the monitor switch de energizes the monitor relay When this occurs a dead short is placed across L1 and L2 The short then blows the F3 fuse which perma nently interrupts power to the Microwave System until all switches are repaired and or functioning properly Figure 18 shows a schematic of the Monitor Circuit Make sure to note the following o Primary and secondary switches interlock the high voltage control signal K2 relay Normal operation When the K2 and relays energize power is supplied to the high voltage transformers Abnormal operation When K2 is energized and K3 is un energ
42. keeping the tip of the meter in contact with and perpendicular to the oven door Record the highest leakage 6 Using the same procedure measure the leakage with the oven door opened to the point just before the primary and secondary switches disengage Record the highest leakage TIP To hold the oven door open for this test back out the top center screw around the perimeter of the oven door Continue backing this screw out until the primary and secondary interlock switches disengage As this point tighten the screw until both switches re engage 7 Using the same procedure measure the leakage around the oven s entire exterior surface Record the highest leakage HOW TO TEST MICROWAVE COMPONENTS Testing the High Voltage Diode The high voltage diode Figure 24 is assembled by connecting several 1000 1500 volt semiconductor diodes in a series to increase the reverse voltage capa bility In the circuit the high voltage diode conducts to prevent the filament voltage from becoming posi tive thus as the high voltage winding of the trans FILAMENT AND HIGH VOLTAGE TERMINALS FIGURE 25 Magnetron former goes to 2400 VPK the high voltage capacitor is charged to 2400 volts When the high voltage wind ing starts to go toward negative the high voltage diode becomes non conducting with the charged
43. necessary NOTE High temperature grease Item 62 must be present between the torsion spring and the switch bracket assembly to ensure smooth action PRIMARY AND SECONDARY INTERLOCK SWITCH ADJUSTMENTS AND PARTS Figure 29 47 NGC 1076 2 Actuator Door 48 102809 Screw 8 32 x 3 8 100P CSK 49 102921 Screw 8 32 x 3 8 50 101557 Screw 4 40 x 1 1 4 51 102012 Interlock Switches 52 NGC 3033 Assy Door Switch See Figure 30 for assembly detail 39 THE OVEN DOOR APPLY HI TEMP GREASE TO AREA 4 TOGGLE SHOULD BE LESS THAN OR EQUAL TO 85 DOWN SWITCH GAP 7 0 020 FIGURE 29 Correct Primary and Secondary Interlock Adjustment and Parts Old Switch Setup DOOR SWITCH ASSEMBLY AND PARTS Figure 30 next page 53 NGC 1072 Bracket Latch 54 102012 Switch Micro 0 1A 125VAC 55 NGC 1087 Spring Door Latch 56 NGC 1073 Toggle Latch 57 101119 Pin Clevis 93 16 x 1 Lg 58 100059 Bearings Bronze 3 16ID x 5 16OD x 1 4 Lg 59 101557 Screw 4 40 x 1 25 Lg PPHD CRES 60 102921 Screw 8 32 x 3 8 Internal Tooth Sems PPHD SS 61 NGC 1126 Plate Door Switch 62 NGC 3006 Grease USDA 1 Food Grade 63 101296 Ring E clip Assembly Notes 1 Ring e clip Item 63 is supplied with Item 56 2 Spring and bracket must be lubricated with high temperature pure FM grease Item
44. remain on The cook cavity will remain at the set temperature and the IR temperature will drop 200 F 104 C below the IRSI This allows fast recovery when the oven is again turned on FIGURE 14 Inserting Smart Card FIGURE 15 Done Screen FIGURE 16 Time Start Screen USER CONFIGURABLE OPTIONS ENABLE DISABLE CODES THE CONTROL SYSTEM 19 The following codes enable and disable each function screen listed They do not take you to the function screen After each code press ENTER To enable press 9 after entering code except 5 W A V E To disable press any key except 9 after entering code Function Screen Done Screen w out Save Time Done Screen w Save Time step 1 Done Screen w Save Time step 2 Edit Recipe Mode Load Menu from Card Save Menu to Card step 1 Save Menu to Card step 2 Snooze Screen Time Screen Figure 16 Timed Mag Test Some codes are not available on some ovens Oven must be in Off or Cooling Down mode Simultaneously Press BACK amp ENTER BACK amp ENTER BACK amp ENTER amp DOWN BACK amp ENTER BACK amp ENTER BACK amp ENTER BACK amp ENTER BACK amp ENTER BACK amp ENTER USER CONFIGURABLE OPTIONS ACCESS CODES Enter Key Code 3 6 6 3 D O N E 3 6 6 3 D O N E 8 4 6 3 T I M E 8 4 3 3 T I D E 6 3 6 8 M E N U 6 3 6 8 M E N U 7 2 8 3 S A V E
45. self test press the corresponding soft key once Press the BACK key to return to the OVEN OFF COOLING DOWN mode Heater Test Screen I Press the HEATER key to turn the heater on Heater will remain on until key is pressed again to turn it off If the blower speed is 0 the blower speed is set to idle airflow 10 Magnetron Screen 1 Press and hold the MGTRON key to test the mag netrons Doing so requires a 5 second warm up period Once the MGTRON key is released the high voltage supply is switched off to the magnetron and the magnetron will stop radiating however the power is still supplied to the magnetron cooling fan for an extra 4 minutes 15 seconds IR ELE Screen 1 Pressing the IR ELE key will turn on the IR element When pressed the screen will read IR ELEMENT ON Press the IR ELE key again to turn it off 15 THE CONTROL SYSTEM Diagnostic Display Screen 2 The DIAG key turns on or off the diagnostic display feature When this feature is enabled the oven will display temperature and cook cycle parameters when the oven is cooking or idle In addition the status indicators are displayed on the bottom of the screen When a status indicator is highlighted backlit the corresponding system is off or open For example would indicate that the Microwave System is off The STATUS INDICATOR section below offers a more detailed description of each indicator COOKS Screen 2 Press once to display the
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47. 0 230 VAC is present Verify control wiring from the motor controller and I O control board specifically low voltage wire OR 9 If all wires are OK then refer to page 50 for motor controller troubleshooting 208 240 230 VAC is not present Correct wiring going to the motor controller Also check fuses Status Indicator A is still highlighted in TEST MODE Refer to page 50 for motor controller troubleshooting F3 Magnetron Current Low Ensure the K2 mechanical relay is in good working order If relay is OK refer to pages 34 35 F3 MAGNETRON CURRENT LOW for detailed troubleshooting F8 Heat Rise Low NOTE This message occurs in WARM UP and SELF TEST if the oven fails to warm up in the prede termined time period 1 Verify the high limit thermostat is not tripped If high limit is tripped reset and allow the oven to warm up If high limit is not tripped proceed to instructions below High limit thermostat is not tripped Check both K4 and K5 SSRs by activating them in TEST MODE activate HEATER and IR ELE When actuated the control input of the SSR will go to 0 00 VDC When the relay is not actuated the input will read 24 00 VDC If the control voltage is not pulled down during actuation verify the wiring between SSR and I O control board Replace SSR if wiring is OK If the control voltage is pulled down Refer to Figure 37 on page 47 THE CONTROL SYSTEM ISS
48. 0 CONTROL BOARD ITEM IDENTIFICATION AND TEST POINT LOCATIONS Figure 40 C9 Capacitor D6 Diode J2 40 Pin Connector for LV Harness J3 3 Pin Connector for VFD Display J4 14 Pin Connector for Keypad J5 26 Pin Connector for Display Data 16 RS 232 Connector Unused Voltage Reference 0 5 VDC RJ11 Connector for Smart Card Cable P3 Blower Controller Pin Configuration U15 EPROM Socket R42 Voltage Reference Adjustment not available on some ovens R51 Beeper Volume Adjustment SKP1 Beeper 19 Erasable EPROM Socket Magnetron Current Transformer 54 1 0 BOARD SCHEMATIC J2 RJ11 U19 RJ11 R51 D6 f N a SN ae Ne T o R42 N nu T1 FIGURE 40 I O Control Board and Test Point Locations opeuio DIN Ip H8unold saam ams mv SHIM JOSSY SANY z
49. 16 Torx Security 102752 46 Screw 8 16 x 1 2 Torx Security Black Oxide 102756 47 Screw 8 18 SS 101701 22 Screw 8 32 x 3 8 102921 29 30 31 32 33 34 46 Screw 8 32 x 3 8 PFH CSK 102809 22 26 29 32 35 Screw 8 32 x 3 8 PPHD SEM SS Internal Tooth 102922 47 Screw 8 32 x 3 8 Torx Security 102748 35 Screw 8 32 x 1 2 Cap 101666 22 Screw 10 32 x 1 2 SS Hex 101381 26 Shield Microwave NGC 1116 39 82 COMPREHENSIVE PART LIST ITEM DESCRIPTION PART NUMBER FIGURE NUMBER PAGES 65 78 Shim 0 030 NGC 1169 1 32 Shim 0 045 NGC 1169 2 32 Shim Door Latch NGC 1132 35 Shim Tool 0 030 NGC 1344 32 Shim Tool 0 060 NGC 1340 32 Shunt Plate Door NGC 3021 35 Smart Card Blank 100508 17 Smart Card Programmed call TurboChef for Part Numbers Varied 17 Spacer Aluminum 1 2 101954 17 Standoff 8 32 F F x 1 101912 31 Standoff 8 32 F F x 1 5 16 Diameter 101914 33 34 Standoff 8 32 M F x 5 16 1 4 Diameter 101915 33 34 Stone Baking Fiber Reinforced NGC 3063 46 Stone Baking Glazed Clear NGC 3038 46 47 Stone Baking Unglazed NGC 3037 46 Support Frame NGC 1047 22 Switch Door Assembly NGC 3033 29 32 Switch Door Component 102012 29 30 31 32 33 34 Tape Aluminum 102698 35 Thermocouple Electrical Compartment EC 700 1199 None Thermocouple Cook Cavity CC NGC 1140 None Ther
50. 1914 Standoff 48 32 F F x 1 5 16 DIA 81 101915 Standoff 48 32 M F x 5 16 1 4 DIA attached to outside of Item 80 82 102921 Screw 28 32 x 3 8 83 101558 Screw 4 40 x 1 125 FIGURE 35 OVEN DOOR ASSEMBLY Chapter 6 The Oven Door Page 44 Oven Door Parts 84 NGC 3067 NGC 3067 2 85 NGC 3021 86 NGC 1061 87 102750 NGC 1216 88 NGC 1076 2 89 NGC 1132 90 102945 91 1138 92 102809 93 1165 94 NGC 1125 1 NGC 1125 2 Door NGC Generic Door NGC SBK Kit Shunt Plate Hinge Block Handle Door Generic Handle Door SBK Actuator Door Shim Door Latch Bolt 1 4 20 x 1 00 Label Precaution 8 32 x 3 8 CSK 100 Label Caution Empty Door Insulation 1 Door Insulation 2 95 NGC 1127 96 102748 97 101688 98 102698 99 NGC 1155 100 101293 101 1170 SERVICE PARTS AND ILLUSTRATIONS Channel Door Handle Screw 8 32 x 3 8 Torx Security Screw 8 x 1 2 PTH Tape Aluminum Name Plate TurboChef Nut Push 1 8 Label Service Includes items 85 101 73 14 SERVICE PARTS AND ILLUSTRATIONS FIGURE 37 CONVECTION CIRCUIT BLOCK DIAGRAM Chapter 7 Convection Circuit Page 47 BOTTOM IR CONTROL WH 28 MAIN HX CON
51. 2 3 Pin Power Cable 26 Pin Ribbon Cable Keypad NGC Standard Keypad NGC SWY Keypad NGC SBK Keypad NGC OUT Smart Card Reader Smart Card Reader Cable Contact TurboChef 800 90TURBO or 1 214 379 6000 for more info part numbers SERVICE PARTS AND ILLUSTRATIONS FIGURE 18 MONITOR CIRCUIT SHOWN IN FAILSAFE STATE Chapter 5 The F3 FUSE 20 AMP BLOWN LJ LINE VOLTAGE Microwave System Page 25 K2 HV RELAY HV TRANSFORMER oloja LINE VOLTAGE L2 24 VDC Er gt HV TRANSFORMER E 67 PRIMARY AND SECONDARY INTERLOCKS CLOSED Menem of 6 e 724 VDC AW MONITOR SWITCH 8 2 OPEN _ Bx CDM L conTRoL FIGURE 20 MICROWAVE SYSTEM PARTS Chapter 5 The Microwave System Page 27 11 NGC 3062 1 NGC 3062 2 NGC 3062 3 12 NGC 3020 NGC 3020 2 100207 13 14 100481 NGC 3030 1 NGC 3030 3 Mag Fan Relay SBK NGC 3030 13 Europe Brazil Single Phase NGC 3030 14 Indiana North Carolina NGC 3030 15 Europe Asia Pacific MPh HV Transformer 2 per oven 1 per kit USA Latin America Korea HV Transformer 2 per oven 1 per kit Europe Asia Pacific HV Transformer 2 per oven 1 per kit Japan High Voltage Capacitor 2 per oven 1 per kit USA Latin America Korea High Voltage Capacitor 2 per oven 1 per kit Europe Asia Pacific
52. 2 To alter a recipe 1 Enter the EDIT MODE see page 16 2 Enter the access code 9 and set the CCSP The screen displays the first set of eight 8 recipe groups To access the second set of eight 8 recipe groups press either the UP or DOWN key 3 Select the recipe group that contains the individ ual recipe you wish to alter Select the recipe you wish to alter by pressing the soft key correspon ding to the recipe item Figures 11 and 12 4 Use the UP and DOWN keys to navigate through the recipe settings Use the keypad and ENTER key to alter any of the following three 3 parameters see Figure 13 FIGURE 12 Select Recipe FIGURE 13 Edit Recipe Settings a Cook time Total duration of the cook cycle Enter the desired time and press ENTER b IR element temperature IRSP The temperature the lower radiant element will maintain during the entire cook cycle Valid temperatures are between 500 F 260 C and 1150 F 621 C c Events 1 6 Use the keypad and ENTER key to enter values for TIME AIR and WAV B Sum of 96 TIME for all events must 100 The operating system will not allow a combination of events not equal to 10096 96 AIR parameter is valid between 10 and 100 D The 96 WAV microwave parameter is valid between 0 and 100 5 After making changes test the recipe by pressing the TEST soft key Once the oven has warmed to the CC set point press the TEST soft key again
53. 2 102805 Left Hinge 43 101381 10 32 x 1 2 Hex SS 44 102140 10 Flat 45 102350 10 Split Lock 46 101191 Cap Hole 70 SERVICE PARTS AND ILLUSTRATIONS FIGURE 29 PRIMARY AND SECONDARY INTERLOCKS ADJUSTMENT AND PARTS OLD SWITCH SETUP Chapter 6 The Oven Door Page 40 Primary and Secondary Interlock Switch Parts 47 NGC 1076 2 Actuator Door 48 102809 49 102921 50 101557 51 102012 52 NGC 3033 Screw 8 32 x 3 8 100P CSK Screw 8 32 x 3 8 Screw 4 40 x 1 1 4 Interlock Switches Assy Door Switch See Figure 32 for Assy Detail FIGURE 30 DOOR SWITCH ASSEMBLY AND PARTS Chapter 6 The Oven Door Page 41 Door Switch Parts 53 NGC 1072 54 102012 55 NGC 1087 56 NGC 1073 57 101119 58 100059 59 101557 60 102921 61 NGC 1126 62 NGC 3006 63 101296 Bracket Latch Switch Micro 0 1A 125VAC Spring Door Latch Toggle Latch Pin Clevis 93 16 x 1 Lg Bearings Bronze 3 16ID x 5 16OD x 1 4 Lg Screw 4 40 x 1 25 Lg PPHD CRES Screw 8 32 x 3 8 Internal Tooth Sems PPHD SS Plate Door Switch Grease USDA H 1 Food Grade Ring E clip ORO APPLY HI TEMP GREASE TO AREA OS SWITCH GAP 0 020 TOGGLE BE LEVEL OR NEARLY LEVEL FIGURE 31 MONITOR SWITCH ADJUSTMENT AND ASSEMBL
54. 542 USA UK Ireland Brazil Japan 1Ph EMI Filter P N 100545 Europe Asia Pacific Australia Japan 3Ph Fan 1 Cooling Fan Magnetron Fan 1 Fuse Holders 1 F2 and Fuse F1 12 Amp Fuse F2 12 Amp Fuse F3 20 Amp Heater Convection Heater IR Element Magnetron M1 Magnetron M2 Motor Convection Power Supply 24VDC PS Relay K1 Filament Relay K2 Anode Relay K3 Monitor Relay K4 K5 Solid State K4 K5 Heater IR Relay K6 Voltage Relay K7 Magnetron Cooling Fan Thermostat OT2 Cooling Fan Thermostat OT1 Heater Transformer Filament FT1 Transformer Filament FT2 Transformer High Voltage T1 Transformer High Voltage T2 Voltage Sensor Module US ovens only Low Voltage Components Display VFD I O Control Board SCHEMATIC COMPONENTS 53 Keypad NGC Oven Switch Primary Interlock Switch Secondary Interlock Switch Monitor Safety Thermocouple CC Thermocouple EC Thermostat Magnetron Wire Harness Replacement P Ns Low Voltage Harness 123 100185 Old Switch Setup NGC 1418 New Switch Setup Line Voltage Harness 124 NGC 1150 1 North America NGC 1150 2 UK Ireland Brazil NGC 1150 3 Eu Asia Pacific Au Japan Magnetron Wire 125 100186 All NGC Ovens Power Cord 126 100187 USA 100194 NGC ED Europe Asia Pacific 100195 UK Ireland Brazil 103187 NGC EW Europe Asia Pacific 103195 Australia NGC 1383 3Ph NGC 1390 1Ph 1
55. 62 3 Assembly must be hand tightened prior to any final adjustment ADJUSTING THE MONITOR SWITCH OLD SETUP The old switch assembly is identifiable by the moni tor switch being located on the right hinge assembly Also the serial number of the oven will follow this formatting X variable digit letter NGC XXXXX North America NGCXX XXXXX International To adjust the switch follow the steps below 1 Ensure the oven door is adjusted Refer to ADJUST ING THE COOK DOOR on page 38 2 Turn on oven and bring it to the set temperature WARNING Oven surfaces are HOT Use extreme caution when making adjustments 3 Open and close the oven door several times to ensure the door closes smoothly and the door actuator Item 47 clears the slot in the flange Reference Figure 29 4 Disconnect oven from power source 5 To adjust the monitor safety switch Figure 31 loosen the 48 32 screw and the two 2 44 40 screws Items 68 and 69 securing the switch 6 Rotate the monitor safety switch Item 65 until the gap between the switch paddle and the switch body is 0 02 0 5 mm 7 Open and close the oven door several times to make certain the adjustment is correct 8 Tighten all screws 9 Reconnect oven to power source 10 Allow oven to sit at the set temperature for 10 minutes and confirm all adjustments MONITOR SAFETY SWITCH PARTS Figure 31 next page 64 102804 Hinge Right 65 102012 Switch
56. 7 6 6 9 S N O Z 8 4 6 3 T I M E 9 2 8 3 W A V E The following codes allow access to each function screen listed To enable disable these codes where applicable see above After each code press ENTER Function Screen Edit Recipe Mode Erase Menu Load Menu from Card Master Reset Save Menu to Card Set PIN Test Mode Unit Test View Cook Counts View Faults Zero Cook Counts Oven must be in Off or Cooling Down mode execute press 3 after entering code Simultaneously Press UP amp DOWN BACK amp ENTER BACK amp ENTER amp DOWN BACK amp ENTER BACK amp ENTER 1 amp 3 4 amp 6 BACK amp ENTER Enter Key Code 9 or as specified see Set PIN below 3 7 2 7 E R A S Bottom left then upper mid soft key 9 4 7 1 Bottom left then lower mid soft key 3 3 4 8 E D I T 9 4 2 8 W H A T 8 6 4 8 U N I T 6 7 3 9 O R E Z Set PIN after entering code Accessing Edit Recipe Mode will now require new PIN instead of 9 To view voltage press ENTER To initiate a self test press the corresponding soft key from the voltage screen 20 THE CONTROL SYSTEM ff IH FIGURE 17 Control System Panel Enclosure and Parts CONTROL SYSTEM PANEL PARTS Figure 17 1 1040 1209 102960 100508 Varies NGC 3023 101954 Cover Keypad Display Std Cover Keypad Display SBK Nut 4 40 Stainless
57. AND MONITOR INTERLOCK SWITCHES NEW SWITCH SETUP 1 2 Disconnect power to the unit Disconnect the 40 pin connector from the I O board to allow maximum clearance Using the 0 060 1 524 mm spacer as a template included with item 74 adjust the secondary switch NOTE This will also adjust the monitor switch Open and close the door several times to verify the switch gap NOTE The absolute maximum gap should not exceed 0 060 1 524 mm Re connect the 40 Pin connector to the I O board and apply power to the unit Simultaneously press BACK and ENTER keys Enter 9 4 2 8 then press ENTER Open the oven door and verify 5 and THE OVEN DOOR 43 77 FIGURE 34 Secondary Monitor Switch Assembly New Switch Setup disengage in sequence 9 Close the oven door and verify the M S and P engage in sequence 10 Energize the Microwave System and open the door 11 Verify the W indicator is backlit meaning the oven microwave system turns OFF when the door is open SECONDARY AND MONITOR SAFETY SWITCH PARTS Figure 33 and 34 77 102804 78 102012 79 NGC 1126 80 101914 81 101915 82 102921 83 101558 Hinge Right Switch Limit Micro x2 Plate Door Switch Standoff 48 32 F F x 1 5 16 DIA Standoff 8 32 M F x 5 16 1 4 DIA attached to outside of Item 80 Screw 8 32 x 3 8
58. HE MICROWAVE SYSTEM MICROWAVE SYSTEM COMPONENTS Below is a description of each component within the Microwave System Magnetron Magnetrons supply the RF energy at 2 45 GHz and begin to oscillate when they are supplied with approximately 4 1KVDC at approximately 350 mA During operation each magnetron will output a nominal 1 kW of power 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 WARNING Never attempt to measure the voltage values of the high voltage trans formers with the high voltage transformers enabled Lethal voltage will be present Reference page 30 for proper measuring technique 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 5 seconds prior to energizing the Microwave Circuit via the high voltage trans formers When in operation the filament trans formers supply approximately 3 15 VAC at 10 amps to each magnetron filament The filament trans formers are controlled via the K1 relay F3 Fuse The F3 fuse is a 20 amp class CC fuse designed to blow in case of an over current scenario such as
59. L z4 995919 SANY 0 4 o of HL HOLOSNNOO LHYNS 7 1
60. Limit Micro 66 NGC 1126 Plate Door Switch 67 101912 Standoff 8 32F Fx1 in S 68 102921 Screw 8 32 x 3 8 69 102902 Screw 4 40 x 5 8 THE OVEN DOOR 41 er 7 Ne FIGURE 30 Door Switch Assembly and Parts Old Switch Setup 84 3 FIGURE 31 Monitor Switch Adjustment and Assembly Old Switch Setup 42 THE OVEN DOOR APPLY HI TEMP GREASE TO AREA FIGURE 32 Primary Switch Adjustment and Parts New Switch Setup ADJUSTING THE PRIMARY INTERLOCK SWITCH NEW SWITCH SETUP The new switch assembly is identifiable by the pri mary switch being located on the left side of the oven Also the serial number of the oven will fol low the formatting below X variable digit letter NGCD 5 thru 9 XXXX North America NGCXXD 5 thru 9 XXXX International 1 When the oven completes BURN IN if required see page 38 closely examine the latch toggle position using the door switch gauge Item 75 2 If the toggle is past the top of the window you must correct the toggle s position by installing an 0 030 Shim Item 76 See Figure 32 3 Verify position of toggle by opening and closing the o
61. M zonas ino 4 EVI HM orya ance 2 an NOISNAL39V LIOA HSIH 3009 THM EW v6 18 t 18 MEM Q33 ANdLAO TOMLNOS 3LIHM HM AfldNI SNLYLS 39NVMO 90A 39V110A 3009 40709 27 06 dIN3 L IH LH A QWADEZ A INIT NMOUS O9VAOEZ A 39V 18 M8 HOLO3NNOO NId 07 dO SNIMVHG TWHIASN 3078 18 39 VL 10A ANI 3009 40109 H3MOd LNOH LIM N3dO HOOd NJAO SMOHS OILVA3HOS 1 SALON 19 91 25 03 29 69 gt Opeusoy zeig DSN SP 14 WVADVIC 15071 gt A gt w n gt Ion jo 63 e w o v e o 5 n 9ILVIN3H9S 1IZVH8 29 SWHO SLIVA 1 13 2 55 12 SdWV 22 55 12 SdWV 22 58915 SdWV el dl 02 2 OVAOETST I J3AZNSDZ dne NADE ALIS 010 5 201831 AL33VS AUVONOISS ON zi 0 7 DN ON m 2 tG td ca d ES 0 f ro Ym m S520 IH3INI 14 5 GNO23S
62. NG The bottom element operates at appx 1000 F 537 C INSTALLATION SPECIFICATIONS AND MAINTENANCE Step 5 Remove Particles and Spray Oven Interior with TurboChef Oven Cleaner Using a damp towel remove large food particles If stubborn stain is present sparingly spray TurboChef Oven Cleaner onto the stain Allow cleaner to penetrate for five 5 minutes DO NOT saturate the bottom of the oven with water or oven cleaner Step 6 Clean Oven Interior Using a nylon scrub pad clean the oven door and cook cavity CAUTION DO NOT apply pressure to the wave guide covers Breaking will result in a non warranty service call Step 7 Wipe Out Oven Interior Wipe oven door bottom element and cook cavity using a damp towel Step 8 Clean Lower Access Panel Area DO NOT spray any chemical in this area Step 9 Lower the Bottom Element and Reinstall the Cooking Surface and Lower Access Panel Step 10 Apply Oven Guard and Clean Oven Exterior Spray Oven Guard on towel Wipe sides of cook cavity and inside of door DO NOT spray Oven Guard directly into cook cavity or wipe on nozzle plates bottom element Wipe the oven exterior with a clean damp towel Oven is ready to turn on 5 Theory of Operation THEORY OF OPERATION The TurboChef NGC Tornado oven utilizes three independent heat transfer mechanisms to rapidly cook food The systems are as follows Convection Infrar
63. NS 24 VDC Power Supply 24 VDC output at 40 watts Supplies control voltage for I O control board 24 VDC mechanical relays and solid state relays Mechanical Relay 240 VAC 30 Amp Double Pole Double Throw 24 VDC Relay Coil Switches power to the magnetron filament transformers K2 Mechanical Relay 240 VAC 30 Amp Double Pole Double Throw 24 VDC Relay Coil Switches power to the magnetron high voltage transformers K3 Mechanical Relay 240 VAC 30 Amp Double Pole Double Throw 24 VDC Relay Coil Safety interlock device designed to short L1 and L2 if the monitor switch opens before the primary or secondary interlock switches K4 K5 SSR 240 VAC Dual 40 Amp Solid State Relay K4 right controls the convection heater and 5 left controls the IR element K6 Mechanical Relay North America Only 240 VAC 30 Amp Three Pole Double Throw 24 VDC Relay Coil Responsible for switching between the 208 and 240VAC taps on the high volt age and filament transformers K7 Relay 24 VDC 20 Amp Sealed Starts with command from I O board switches magnetron cooling fan on and off Timer for switching off mag fan is 4 15 after filament switches off Interlock Switches Primary Secondary and Monitor Interlock Switches Must be actuated by the oven door When the door opens the order is 5 IR Thermocouple Type K Thermocouple Embedded in the IR ele ment the IR thermocouple measures the inter
64. Oven 18 NGC 1217 2 4 Page 4 Cart TurboChef Oven 24 NGC 1217 1 4 Page 4 Catalytic Converter NGC 1012 39 Channel Door Handle NGC 1127 35 Clamp Blower Seal NGC 1023 38 Cleaner TurboChef Oven Domestic 103180 None Cleaner TurboChef Oven International 103380 None Cleaner Wave Guide Cover Domestic 103183 None Cleaner Wave Guide Cover International 103383 None Clip Catalytic Converter Standard NGC 1030 39 Clip Catalytic Converter SBK NGC 1233 39 Cord Power Australia 103195 None Cord Power Japan 1Ph NGC 1390 None Cord Power Japan 3Ph NGC 1383 None Cord Power NGC ED Europe Asia Pacific 100194 None Cord Power NGC EW Europe Asia Pacific 103187 None Cord Power UK Ireland Brazil 100195 None Cord Power USA 100187 None Cover Bottom Front Standard NGC 1071 2 46 Cover Bottom Front SBK NGC 1212 47 Cover Cooling Fan NGC 1082 46 47 Cover Keypad Display Standard NGC 1040 17 Cover Keypad Display SBK NGC 1209 17 Cover Left Side Standard NGC 1069 1 46 Cover Left Side SBK NGC 1213 1 47 Cover Motor NGC 1081 38 Cover Right Side Standard NGC 1069 2 46 Cover Right Side SBK NGC 1213 2 47 Cover Top Standard NGC 1068 46 Cover Top SBK NGC 1211 47 Cover Wave Guide NGC 3036 22 Diode HV 100481 20 Display NGC 3023 17 Door Standard NGC 3067 26 35 Door SBK NGC 3067 2 26 35 80 COMPREHENSIVE PART LIST ITEM DESCRIPTION PART NUMBER FIGURE NUMBER PAGES 65 78
65. Red White Winding B C 2 0 2 6 Ohms Black White Green Windings to Chassis Open or Red IR Element and Catalytic Converter The IR Element and Catalytic Converter provide two very different but essential functions The IR element provides the bottom browning similar to a residual broiler or salamander type cooking appliance required for cooking most food items The IR element temperature is independently controlled in each recipe The catalytic converter scrubs the air to eliminate VOCs and grease particulates that are liberated during the cooking process It is important to properly care for the catalyst using only TurboChef Oven Cleaner P N 103180 USA 103380 Intl and distilled water For more detailed information see the catalytic converter section below COMPONENTS IR Element The IR element a dual coil type heater is located in the bottom of the oven cavity The first coil is the heating coil The second is the IR thermocouple wire The heating coil outputs 3000 watts at 208 VAC The heating coil s resistance is 14 4 ohms at room temperature The thermocouple coil is a Type K thermocouple with a resistance of approximately 20 ohms at the splices located approximately 6 inches from the heater and 40 ohms measured at the extension wires at the I O control board The IR element is controlled via the K5 solid state relay and the IR thermocouple via the I O control board Catalytic Conv
66. Step 4 terminals F FA should indicate a reading of less than 1 ohm Figure 25 4 A continuity check between either filament terminal and the magnetron chassis should indi cate an infinite resistance open How to Check a High Voltage or Filament Transformer 1 Disconnect the AC power source and discharge the high voltage capacitors 2 Disconnect all the wires in question going to the transformer How to Check a Magnetron for Open Shorted Filament 3 Use an ohmmeter to check the impedance of the 1 Disconnect the AC power source and discharge the high voltage capacitors 2 Isolate the magnetron from the circuit by removing the wires from the F and FA terminals Figure 25 primary and secondary winding Refer to the high voltage and filament transformer table below to determine if the transformer is OK If the resistance is different then the table indicates replace the transformer HIGH VOLTAGE AND FILAMENT TRANSFORMER RESISTANCE TABLE HIGH VOLTAGE TRANSFORMERS PRIMARY VOLTAGE FREQ TAPS AND RESISTANCE SECONDARY TAPS AND RESISTANCE NGC 3062 1 208 VAC 60 Hz 1 amp 2 0 819 1 001 0 240 VAC 60 Hz 1 amp 3 0 972 1 188 0 4 Ground 53 60 65 52 0 NGC 3062 2 230 VAC 50 Hz 1 amp 2 0 972 1 188 0 3 Ground 57 52 70 30 0 NGC 3062 3 200 VAC 50 60 Hz 1 amp 2 0 784 0 958 3 Ground 55 75 68 13 0 FILAMENT TRANSFORMERS PRIMARY VOLTAGE FREQ TAPS
67. TROL WH 30 Ari ee mL Hm HX ELEMENT 32 C 08540 3300 WATTS 9 919 20a 13 1 OHMS SSR 1510 C gc K5 K4 mm BOTTOM IR B2 3000 WATTS BI Al 14 4 OHMS LI MOTOR SPINS COUNTER CLOCKWISE FROM BACK M4 GREEN 4 TERES MI BLACK 1 OUT BMSC RD 24 SPD 2 BK 25 WH 31 200 240 BK 32 2 VACIN STATUS OK 5 OR 9 6 1 0 GROUND GREEN 12 SERVICE PARTS AND ILLUSTRATIONS FIGURE 38 CONVECTION CIRCUIT ASSEMBLY AND PARTS Chapter 7 Convection Circuit Page 48 Convection Circuit Parts 102 101688 103 NGC 1081 104 100906 Screw 8 x 1 2 PTH Cover Motor Nut 1 4 20 Flange 105 NGC 1025 Assy Blower Motor 106 NGC 3007 107 NGC 1024 108 NGC 1023 109 101688 110 NGC 3011 111 100443 Kit Fan Blade Sealing Block Blower Clamp Blower Seal Screw 8 x 1 2 PTH Heater Convection Controller Motor 112 NGC 3005 Relay K4 K5 SSR 113 100592 Fuses Fl and F2 12 Amp 114 102075 High Limit Thermostat 115 NGC 1043 Gasket Convection Heater fentire motor is needed order NGC 1025 If only hardware screws nuts or seal is needed contact 800 90TURBO or 1 214 379 6000 Not shown for clarity 75 76 SERVICE PARTS AND ILLUSTRATIONS FIGURE 39 IR ELEMENT AND CATALYTIC CONVERTER PARTS AND ASSEMBLY Chapter 8 IR Element and Catalytic Converte
68. The oven will begin to warm up to its prede fined cooking temperature This takes approxi mately 13 minutes When the warm up cycle is completed the oven will beep and display the READY TO COOK FIGURE 4 Properly Stacked NGC Ovens DAILY MAINTENANCE FOR THE NGC Before cleaning check with the store for custom cleaning instructions When cleaning the oven use only TurboChef Oven Cleaner Any other cleaning products can damage critical parts and may void warranty on those parts Supplies and Equipment TurboChef Oven Cleaner P N 103180 USA 103380 Intl Oven Guard P N 103181 USA 103381 Intl nylon scrub pad cleaning towel Step Prepare the Oven Turn oven off by pressing the BACK key The oven will display OVEN OFF COOLING DOWN DO NOT attempt to clean oven during the cool down cycle Cooling takes appx 90 minutes WARNING The oven operates at appx 500 F 260 C and may cause injury if not allowed time to cool properly Step 2 Remove the Lower Access Panel o Wipe any crumbs that have collected Step 3 Remove and Clean the Cooking Surface If rack wash rinse and sanitize If baking stone gently dry scrub with nylon pad If the stone gets wet let it thoroughly air dry Step 4 Lift Bottom Element Be sure the bottom element is cool prior to lifting WARNI
69. UE RESOLUTION F2 Cook Temperature Low 1 Verify the high limit thermostat is not tripped o If high limit is tripped reset and allow the oven to warm up o If high limit is not tripped follow the instructions below High limit thermostat is not tripped Place a small water load in a microwave heat resistant container approx 275 ml in the oven and place the oven in TEST MODE Press the MGTRON key to actuate the microwave While holding down the MGTRON key watch the CC and IR temperatures If either temperature bounces substantially there may be a noise EMI problem To correct this problem examine the wire routing for each thermocouple wire If the wires are routed near any high voltage components such as the magnetron or high voltage transformers re route the wires If this does not correct the problem verify that both magnetrons are securely mounted Call Technical Support for further details at 800 90 TURBO or 1 214 379 6000 23 The Microwave System The Microwave System is the most complex system the oven Proper care must be taken during servicing to protect both the operator and technician VOLTAGE DOUBLER CIRCUIT DESCRIPTION The Microwave System consists of a magnetron and Voltage Doubler Circuit The Voltage Doubler Circuit consists of a special step up transformer a capacitor and a diode MONITOR CIRCUIT DESCRIPTION In addition to understanding the Voltage Doubler Circuit it is
70. UTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY a DO NOT operate or allow the oven to be operated with the door open b Make the following safety checks on all ovens to be serviced before activating the magnetron or other microwave source and make repairs as necessary 1 interlock operation 2 proper door closing 3 seal and sealing surfaces arcing wear and other damage 4 damage to or loosening of hinges and latches 5 evidence of dropping or abuse c Before turning on microwave power for any service 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 A microwave leakage check to verify compliance with the Federal performance standard should be performed on each oven prior to release to the owner 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
71. VACIN STATUS OK 5 OR 9 1 0 6 GROUND GREEN L2 FIGURE 37 Convection Circuit Block Diagram 48 THE CONVECTION CIRCUIT FIGURE 38 Convection Circuit Assembly and Parts Item 105 Blower Motor Detail CONVECTION CIRCUIT BLOWER MOTOR PARTS Figure 38 102 101688 103 NGC 1081 104 100906 105 NGC 1025 106 NGC 3007 107 NGC 1024 108 NGC 1023 109 101688 110 NGC 3011 111 100443 Screw 8 x 1 2 PTH Cover Motor Nut 1 4 20 Flange Assy Blower Motor Kit Fan Blade Sealing Block Blower Clamp Blower Seal Screw 8 x 1 2 PTH Heater Convection Controller Motor 112 NGC 3005 Relay K4 K5 SSR 113 100592 Fuses 1 and F2 12 Amp 114 102075 High Limit Thermostat 115 NGC 1043 Gasket Convection Heater If entire motor is needed order NGC 1025 If only hardware e g screws nuts or seal is needed call 800 90TURBO or 1 214 379 6000 Not shown for clarity Assembly Notes Cut insulation covering heater as shown THE CONVECTION CIRCUIT CONVECTION CIRCUIT TROUBLESHOOTING ISSUE RESOLUTION F8 Heat Low 1 Check that the blower motor is moving air Blower motor is not moving air Check blower motor assembly Oven Not Warming Up and verify motor is stalled Unplug oven and correct obstruction or replace motor For access to motor shaft remove top panel
72. Y OLD SWITCH SETUP Chapter 6 The Oven Door Page 41 Monitor Safety Switch Parts 64 102804 Hinge Right 65 102012 Switch Limit Micro 66 NGC 1126 Plate Door Switch SERVICE PARTS AND ILLUSTRATIONS 71 67 101912 Standoff 8 32F Fx1 in S 68 102921 Screw 48 32 x 3 8 69 102902 Screw 4 40 x 5 8 FIGURE 32 PRIMARY INTERLOCK ADJUSTMENT AND PARTS NEW SWITCH SETUP Chapter 6 The Oven Door Page 42 APPLY HI TEMP GREASE TO AREA Primary Safety Switch Parts 70 102809 Screw 48 32 x 3 8 71 102921 Screw 48 32 x 3 8 72 101555 Screw 4 40 x 3 4 73 102012 Interlock Switch 74 NGC 3033 Assy Door Switch 100P CSK 75 Adjustment Tools included with Item 74 NGC 1215 Door Switch Gauge NGC 1340 Shim Tool 0 060 NGC 1344 Shim Tool 0 030 76 NGC 1169 1 Shim 0 030 NGC 1169 2 Shim 0 045 SERVICE PARTS AND ILLUSTRATIONS FIGURES 33 AND 34 SECONDARY AND MONITOR SWITCH ADJUSTMENT AND ASSEMBLY NEW SWITCH SETUP Chapter 6 The Oven Door Page 43 77 Secondary and Monitor Safety Switch Parts 77 102804 Hinge Right 78 102012 Switch Limit Micro x2 79 NGC 1126 Plate Door Switch 80 10
73. Z NIHSINI ees 2 JEW p a m 4212 uO sug HOLINOW ls UN PE a La eS e3 2 Ona SY 5 HE 2 16 aul ver a aee 5 Sm 212 uno own s z 19 ozn 3 5 nsri eT IUS anse 23 VIN Aso y med QI e cold 19 9 BIB x DAIN LA EXM sado SN3A3 1 i 2 Ae AHUN AHZIN DA a sion anion g 24779 m B p er AYER GU E E AAAA at 21 1 S s v noo on mew Ee ee See 10 HLW YT TG HOLINON EM w 4 2 e SUJAHOJSNVUL AH T Lond d b Z OYN 3HIM 39 VLTIO HH 28 asvnae LOVIN HO SHIM SOWLTOA IH HM a Ova ove Hy strane NOISN3L 3OVLL TOA 4000 er na TR ia 034 108110 TOYLNOD 3LIHM HM LNANI SNLVLS SONVYO OF NOWNOO v X9Y19 Mg 39VL10A 3000 40100 2 dWAL IH IH OvAOEZ A 2 2 A NMOYS H8 OVA0E2 A INIT NOVIA HO O3NNOO NId 0F JO 3018 78 39V110A 3002 40102 G3r1ddv H3MOd LNOHLIM N3dO HOOG HLIM NJAO SMOHS OILVW3HOS L SALON 1g 9ILVIW3H9S AN ION OPeUIOT EF AUNDIA dNlas S490 1831NI AL34VS
74. a high voltage transformer or capacitor failure The fuse also blows if the Monitor Circuit trips the failsafe High Voltage Capacitors Capacitor rating is 0 91uF 2500 VDC for USA Mexico Brazil and S Korea Capacitor rating is 1 15 uF 2500 VDC for Europe Asia Pacific Australia UK Ireland and Japan 50 Hz Capacitor rating is 0 85 uF 2500 VDC for Japan 60 Hz High Voltage Diodes Rated at 16 kVDC Monitor Relay K3 The monitor relay acts as a failsafe device the Voltage Doubler Circuit In its normal un ener gized position the monitor relay shorts L1 and L2 If the K2 relay energizes the high voltage trans formers while the K3 relay is un energized the F3 fuse will blow Magnetron Thermostats The magnetron thermostats are open on rise ther mostats These thermostats are designed to open at 212 F 100 C which triggers an F5 fault NOTE Both magnetron thermostats are wired in series If one opens the control will switch off both magnetrons until the thermostats close The thermostats are self resetting Magnetron Cooling Fan The magnetron cooling fan supplies cooling air for both magnetrons The fan operates at 208 or 240 USA 230 Intl 200 Japan 220 Latin America VAC and is controlled via the K7 relay see Item 14 on Figure 20 If the oven does not have this relay installed it is required that you order the relay kit through Customer Service See page 27 item 14 for part
75. aces DO NOT allow children to use this appliance DO NOT use corrosive chemicals or vapors in this appliance it is not designed for industrial or laboratory use DO NOT operate this appliance if it has a damaged cord or plug is not working properly or has been damaged or dropped See POWER CORD REPLACEMENT page ii DO NOT cover or block any openings on the appliance DO NOT store this appliance outdoors DO NOT use this product near water 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 of this manual on page 5 for proper cleaning procedures REDUCING FIRE RISK o m m Remove wire twist ties from paper or plastic bags used to facilitate cooking in the oven If materials inside the oven ignite Keep oven door closed Turn oven off Disconnect the power cord or shut off power at the fuse or circuit breaker panel If smoke is observed switch off or unplug the oven Keep the door closed to stifle any flames DO NOT use the cook cavity for storage purposes DO NOT overcook food Carefully attend the oven if paper plastic or other combustible materials are placed inside the oven to facilitate cooking DO NOT leave paper products cooking utensils or food in the cavity when not in use SAVE THESE INSTRUCTIONS INTRODUCTION PRECA
76. and remains in warmup for an addi tional 8 minutes to allow cook cavity surfaces to warm The oven will proceed to soak only if warm up was initiated when lt CCSP 126 F or TCC lt CCSP 66 C Cook Cycle A period of operation as defined by a recipe Test Mode A special diagnostic mode that enables the service technician to turn on and off all oven systems independent of one another check oven statistics and set the IRSI THEORY OF OPERATION Keypad The primary interface for the operator Display Displays all visual information to the operator Self Test STEST A special diagnostic function that tests all critical subsystems to determine their operational state Recipe A set of user defined Events that determine a cook cycle Events A single operational element that is a part of a recipe Each recipe may have up to six events depending on programming Each event can be set between 0 and 100 of the total cook time Total Cook Time The total duration of a recipe Percentage Time An event subset that specifies the duration of the event The sum of all event time percentages for a recipe must equal 100 Percentage Air An event subset that specifies the relative amount of impingement airflow speed of convection motor dur ing an event Valid between 10 and 100 NOTE Maximum 100 7100 RPM blower motor speed Blower motor speed scale is linear Percentage Microwave WAV An event subs
77. atic Europe Asia Pacific 230 VAC NGC 1176 4 46 47 Label Schematic Europe Asia Pacific 400 VAC NGC 1176 3 46 47 Label Schematic USA NGC 1176 1 46 47 Label Schematic UK Ireland NGC 1176 2 46 47 Label Schematic Standard Latin America NGC 2020 46 Label Schematic SBK Latin America NGC 2011 8 47 Label Service Assistance NGC 1177 46 47 Label Service Number NGC 1170 35 Latch Bracket NGC 1072 30 Latch Spring Door NGC 1087 30 Leg 4 Black Plastic 100785 46 Leg 4 Standard Stainless Steel 100781 46 Leg 4 SBK 100784 47 Leg 7 SBK Kit 4 legs NGC 3068 47 Magnetron NGC 3015 20 21 Motor Controller 100443 38 Nameplate TurboChef NGC 1155 35 Nut Crescent Keps Hex 8 32 External Tooth 102692 46 47 COMPREHENSIVE PART LIST 8 ITEM DESCRIPTION PART NUMBER FIGURE NUMBER PAGES 65 78 Nut Flange 1 4 20 100906 38 Nut M5 Yellow Zinc Magnetrons Bottom Electrical Plate 100101 None Nut Push 1 8 101293 35 Nut Stainless 94 40 102960 17 Pad Abrasive Non Slip NGC 1187 46 47 Pin Clevis 3 16 Diameter x 1 Long 101119 30 Plate Door Switch NGC 1126 30 31 33 34 Plug Hole Black 1 2 Diameter 101191 46 47 Rack Raised NGC 3064 46 47 Rack Recessed NGC 1274 46 Rack Standard NGC 1064 1 46 Reader Smart Card 100506 17 Relay K1
78. ble for com P P pensating any extra time required to service the prod uct due to removing the product for serviceability Installation Near Open Heat Source Figure 3 When placing a TurboChef oven near an open heat source strictly adhere to the following m clearance on top and minimum 2 51 mm of clearance on each side If the oven is being placed near a grill or stove there must be a divider 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 there must be a divider 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 23 584 mm INSTALLATION SPECIFICATIONS AND MAINTENANCE Oven Restraint Kit TC3 0242 KIT The Oven Restraint Kit is an optional system that helps prevent the oven from moving forward during use and or cleaning It will not prevent the oven from falling off a countertop if the legs are allowed to slide off the edge or if the oven is intentionally or forcefully pulled off Proper installation instructions are included with the kit for additional information please call customer service at 800 90TURBO 1 214 379 6000 SETUP AND INITIAL OPERATION Setup Once the oven is properly positioned on the counter remove any packing material and or any foreign objects from within the
79. cal circuits if possible Route intercom wires microphone wires speaker cables etc away from the oven Installation Specifications and Maintenance FIGURE 1 NGC Tornado Dimensions SPECS AND DIMENSIONS Dimensions EXTERIOR COOK CAVITY Height 19 483 mm 8 203 mm with legs 23 584 mm Width 26 660 mm 15 5 394 mm Depth 25 7 653 mm 14 7 373 mm with handle 28 2 716 mm Weight 190 lbs 86 kg WALL CLEARANCE Back Sides 0 0 mm unless built in page 2 2 51 mm ENTRY CLEARANCE minimum Crated 31 5 800 mm Uncrated 28 7 729 mm Construction EXTERIOR 430 stainless steel front top and sides 4 102 mm adjustable legs Cool to the touch handle INTERIOR 304 stainless steel line Fully insulated cooking chamber Removable assorted cooking surfaces Independently controlled lower cooking element INSTALLATION SPECIFICATIONS AND MAINTENANCE Standard Features Recirculating airpath with patented catalytic converter system Multi speed convection blower Independently controlled bottom browning element Stackable design Smart Voltage Sensor Technology North America only Factory programmed customizable menu settings Smart Card for remote programming 0 0 H 0 0 Warranty 1 year parts and labor Certifications UL cUL NSF FDA FCC TUV ANSIINSF 4 81Y5 UL KNLZ Ventless Certificatio
80. e conclusion of the following service tasks Door removal replacement and or adjustment Wave guide removal and or replacement Magnetron removal and or replacement THE MICROWAVE SYSTEM 3l FIGURE 23 Microwave Survey Meter Placement WARNING If the unit fails the radiation test leakage greater than 4 mW cm the oven must be taken out of service immediately until the defect is corrected In addition the CDRH Regulations 21 Subpart C 1002 20 requires that leakage readings of over 4 mW cm must be reported to the manufacturer Procedure for Measuring RF Leakage 1 Place the oven in WARM UP and allow it to warm up to the set temperature CCSP This should take approximately 13 minutes if the oven is starting out cold 2 Once the oven has warmed up place the oven into TEST MODE see page 14 Place a water load into the cook cavity Water load must con form to the following specification a Volume 275ml 15ml b Temperature 68 9 F 20 5 C c Vessel Low form 600 ml beaker with an inside diameter of approximately 3 35 85 mm and made of Pyrex or glass ceramic 3 Position the microwave survey meter as shown in Figure 23 4 Press and hold the MGTRON soft key to energize the Microwave System 32 THE MICROWAVE SYSTEM FIGURE 24 High Voltage Diode While holding MGTRON soft key move the sur vey meter around the outline of the oven door
81. ed energy Microwave energy By combining these mechanisms along with the ability to control each mechanism independently the NGC Tornado oven is able to reduce the cook time of most foods by 70 90 percent Figure 5 below represents the oven s different sys tems and the critical components of each system THEORY OF OPERATION Should a problem arise with any of the compo nents listed below please turn to the appropriate section within this manual for further instructions For the purpose of this manual each independent heat transfer mechanism is individually identified For instance if an oven is experiencing difficulties browning the food focus on CONVECTION SYSTEM and or BOTTOM IR AND Focus on MICROWAVE SYSTEM if the oven is browning the food but not heating the inside Part numbers are included on illustrations where applicable and in the back of this manual If an item is not illustrated the part number is provided in the text Chapter 4 CONTROL SYSTEM Control Board Keypad Display Mechanical Relays Solid State Relay Chapter 5 MICROWAVE SYSTEM Magnetrons High Voltage Transformers Filament Transformers High Voltage Capacitors High Voltage Diodes Fuses FIGURE 5 NGC Tornado Systems and Critical Components Chapter 7 CONVECTION SYSTEM Convection Heater Blower Controller Blower Motor Hi Limit Thermostat Chapter 8
82. eg NGC Black Plastic Leg NGC Stainless Steel Hole Plug 1 2 Dia Black Assy Keypad Display Cover Standard Assy Keypad Display Cover Subway Rack Standard USA NGC 1274 NGC 3064 138 NGC 3037 NGC 3038 NGC 3063 139 NGC 1176 1 NGC 1176 2 NGC 1176 3 NGC 1176 4 NGC 2020 140 NGC 1177 141 NGC 1148 142 102962 143 NGC 1187 144 NGC 1082 L x3 per panel Rack Recessed International Rack Raised Stone Unglazed Stone Clear Glazed Stone Fiber Reinforced Label Schematic N America Label Schematic UK Ireland Label Schematic Eu Asia Pac 400VAC Label Schematic Eu Asia Pac 230 VAC Label Schematic Gen Brazil Label Service Assistance Label Caution Hot Nut KEPS HEX 8 32 Ext Tooth CRES Pad Abrasive Non slip Cover Cooling Fan 78 SERVICE PARTS AND ILLUSTRATIONS FIGURE 47 COVERS AND MISCELLANEOUS PARTS SBK OVENS Covers and Miscellaneous Parts SBK 145 NGC 1213 1 Cover Left Side 146 NGC 1213 2 Cover Right Side 147 NGC 1211 148 102756 149 101691 150 102922 151 NGC 1212 152 100784 153 101191 Cover Top Screw 8 x 1 2 Lg TORX HD Security Screw 8 Serrated Phillips TRHD CRES Screw 48 32 x 3 8 PPHD SEM Int Tooth SS Cover Bottom Front Leg NGC SBK 4 qty 1 Hole Plug 1 2 Dia Black 154 NGC 1054 3 Assy Keypad Display Cover 155 NGC 3064 Rack Raised 156 137 158 159 160 161 162
83. em Parts Microwave System Components Wave Guide Cover Replacement Wave Guide Wave Guide Cover Parts Wave Guide Replacement High Voltage and Filament Transformer Replacement Wiring the High Voltage Transformers Wiring the Filament Transformers Measuring RF Leakage for Microwave Safety How to Test Microwave Components Testing the High Voltage Diode How to Check a Diode How to Check a Capacitor How to Check a Magnetron for Open Shorted Filament How to Check a High Voltage Transformer or Filament Transformer High Voltage and Filament Transformer Resistance Table Microwave System Troubleshooting Chapter 6 The Oven Door Removing Reinstalling the Oven Door Oven Door Parts Adjusting the Oven Door Preparing the Oven for Switch Adjustment Oven Burn In Procedure Adjusting the Primary and Secondary Interlock Switches Old Switch Setup Primary and Secondary Interlock Switch Adjustments and Parts Door Switch Assembly and Parts Adjusting the Monitor Safety Switch Old Switch Setup Monitor Safety Switch Parts Adjusting the Primary Interlock Switch New Switch Setup Primary Switch Adjustment and Parts Adjusting the Secondary and Monitor Interlock Switches New Switch Setup Secondary and Monitor Safety Switch Parts Oven Door Assembly Oven Door Parts Screw Torque Chart Interlock Switch Troubleshooting 18 19 19 20 21 25 25 26 26 28 29 30 30 30 30 31 31 32 32 32 33 33 33 33 34 37 37 38 38 38 38 39 40 40 40 42 42
84. erter The catalytic converter a VOC type catalyst is locat ed behind the inside cook cavity wall and is responsi ble 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 IR ELEMENT AND CATALYTIC CONVERTER of the airflow thus the grease burns and breaks down into CO and H O as it passes through the catalytic converter The catalyst will operate most efficiently at temperatures above 475 F 246 C The catalyst material is very sensitive to certain chemical compounds Irreversible damage can occur if the catalyst is exposed to cleaning chemicals con taining phosphates NaOH silicates Na and Potassium Salts These chemicals are found in most commercial degreasers and cleaners therefore only TurboChef Oven Cleaner should be used CAUTION Clean the catalytic converter with TurboChef Oven Cleaner and rinse thoroughly with distilled water Let the catalytic converter air dry before reinstalling If TurboChef Oven Cleaner is not available do not use a substi tute Use distilled water only IR ELEMENT AND CATALYST REMOVAL Refer to Figure 39 and the instructions below for removing the IR element and catalytic converter Removing the IR Element 1 Unplug the oven 2 Disconnect the heater wires going to the EMI filter and the high limit thermostat 3 Locate where the IR
85. et specifying the microwave cycle during the event Valid between 0 and 100 For example if WAV is set to 30 then microwave would be present in the cook cycle for 3 out of every 10 seconds Fault Code A code assigned to an instance that the control considers to be a failure Upon discovering a fault the control will display the fault code and a brief description of the failure The oven will also log faults F1 through F6 in the Fault Log See page 11 for more detail on faults and for viewing the fault log Fault Codes The NGC Tornado oven has the ability to continually monitor and log various fault conditions Some fault conditions will terminate cook cycles while others will not Please refer to the fault code table on page 12 for more detailed information When a fault is detected the Fault Log will incre ment However if the fault is subsequently cleared by some action whether service related or not the Fault Log will not decrement TO VIEW FAULT CODES To view the Fault Log simultaneously press the 4 and 6 keys while the oven is in the OFF STATE The oven will display all faults logged Figure 6 Each fault will log up 255 instances before rolling back to zero To zero the log see pages 14 15 TEST MODE NOTE The Fault Log also displays cook counts which will log up to 65 535 cook cycles In order for the control to log a cook cycle the oven must complete the first event of any given recipe Ifa rec
86. gs for different countries If the meter reads 0 VAC the high voltage transformers are most likely wired 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 returning the oven to service as the voltages must be NORTH AMERICA 208 VAC between 1 amp 2 and 240 between 1 amp 3 LATIN AMERICA 220 VAC H JAPAN 200 VAC H INTERNATIONAL 230 VAC NOTE The terminals with the orange dot or the orange wire always go to terminal 3 on USA models Wiring the Filament Transformers The installation of filament transformers is straightforward Filament transformers are wired in phase and in line Refer to the schematics on pages 55 63 detailing the proper wiring Specifically FT1 and FT2 are located in the middle far right edge of the schematics To verify correct wiring North America meas ure the voltages between terminals 1 amp 2 and 1 amp 3 on and FT2 The voltages must be 208 and 240 VAC respectively 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 and FT2 The volt age must be 220 VAC Latin America 200 VAC Japan or 230 VAC International MEASURING RF LEAKAGE FOR MICROWAVE SAFETY An RF microwave leakage test must be performed at th
87. il style heater rated at 3300 watts at 208 VAC with a resist ance of 13 11 Ohms The convection heater is controlled by the K4 solid state relay Convection Motor The convection motor is a brushless AC switch reluc tance type Its top speed is 7100 RPM at 1 HP The motor is controlled by a proprietary controller BOTTOM IR CONTROL THE CONVECTION CIRCUIT 47 Motor Controller BMSC The motor controller is proprietary and will only operate the convection motor described above The motor controller is controlled on command from the control board and 0 10VDC speed command from the I O control board High Limit Thermostat The high limit thermostat is a 250 VAC 3 pole manual reset thermostat with a trip point of 572 F 300 C The thermostat which interrupts power to both the main convection heater and the IR element should never operate during normal oven operation WH 28 MAIN HX CONTROL WH 30 HX ELEMENT 32 3l T 3300 WATTS is 22 C 2 13 1 OHMS i HT520 1 SSR BL510 LA 12 M K5 K4 EE BOTTOM IR B2 A2 3000 WATTS Bl Al 14 4 OHMS 2 L2 LI MOTOR SPINS COUNTER CLOCKWISE FROM BACK 4 GREEN M3 WHITE 4 M2 RED 3 S PHASE MI BLACK 1 OUT BMSC RD 24 yocom 2 BK25 s 200 2400 2
88. ipe has only one event the oven must complete the entire cook cycle in order to count it FAULT CODE DEFINITIONS Fi Blower Running Status Bad Fault is displayed when the motor controller indicates no running status The motor and motor controller are monitored con tinuously in all modes with special handling in SELF TEST and TEST MODE Ifa fault is detected the con trol will terminate a cook cycle and display F1 BLOWER Upon turning on the oven the control will attempt to restart the motor If the restart is suc cessful the fault code will be cleared The fault is also cleared from the display at the onset of cooking or when the blower motor is tested in TEST MODE FAULT CODES NGCVXXXX S NXXXXXX 600 eo FLBLOWER F2 LOW TEMP F3 MAGCURR F4 MONITOR F5 MAGTEMP F6 TEMP FIGURE 6 Fault Log F2 Cook Temperature Low Fault is displayed if the cook cavity temperature is more than 84 F 47 C below the set temperature after five 5 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 the TEST MODE F3 Magnetron Current Low Fault is displayed when the current transformer CT on the I O control board does not detect enough current The fault is monitored when the microwave is on during a cook cycle or self test The fault is cleared from the d
89. isplay at the onset of a cook cycle if the CT detects current or when the magnetron is successfully energized in TEST MODE F4 Door Monitor Defective Fault is displayed when the control detects that the monitor interlock switch unlatches before the pri mary or secondary interlock switches In addition this fault will blow the F3 fuse if the microwave high voltage system is energized when the fault occurs The fault is cleared from the display when the oven is powered off and then back on FAULT CODES NOTE Door interlock switches are in parallel See OVEN SCHEMATICS pages 55 63 The fault is moni tored during a cook cycle or in SELF TEST when the microwave is on F5 Magnetron Over Temperature Fault is displayed when either magnetron thermo stat is open The fault is cleared from the display at the onset of a cook cycle if the thermostat is closed or when the magnetron is successfully tested in TEST MODE 6 EC Electrical Compartment Temperature High Fault is displayed when the EC thermocouple exceeds 158 F 70 C It is monitored once per minute The fault is cleared from the display when the EC FAULT CODE TABLE thermocouple temperature is below the indicated limit F7 Thermocouple Open Fault does not log in counter Fault is displayed when the control detects that either the IR or CC thermocouple is open 999 F C indicates CC thermocouple is open 1999 F C indicates IR ther
90. ized via an opening of the monitor switch L1 and L2 short to blow the F3 fuse and failsafe Figure 19 on the following page details the theory of operation of the Voltage Doubler Circuit PRIMARY AND SECONDARY K2 HV INTERLOCKS CLOSED F3 FUSE RELAY HV TRANSFORMER Zn 20 5 43 ug IP n LINE VOLTAGE BLOWN M i o 4 CONTROL A 3 t NO CDP 24 VDC T2 NC HV TRANSFORMER CONTROL y K3 MONITOR bea i LINE VOLTAGE RELAY L2 7 9 3 oT 6 MONITOR SWITCH pH OPEN __ CDM CONTROL NC FIGURE 18 Monitor Circuit shown failsafe state 25 26 THE MICROWAVE SYSTEM TRANSFORMER OUTPUT VOLTAGE MAGNETRON VOLTAGE 2400 V 0 0 2400 V 4800 V 2400 2400 r j PM 2400 Current 2400 Current gt a Y Flow V Y Flow T lt q CAPACITOR CHARGES CHARGED CAPACITOR PLUS TRANSFORMER ON POSITIVE VOLTAGE SWING ON NEGATIVE VOLTAGE SWING FIGURE 19 Voltage Doubler Circuit Theory of Operation VOLTAGE DOUBLER THEORY OF OPERATION MICROWAVE SYSTEM PARTS Figure 19 Figures 20 and 21 1 The high voltage transformer steps up the input 11 NGC 3062 1 HV Transformer 2 per oven 1 voltage to approximately 2400 volts peak 4800 per kit
91. l ovens ct wire for amp reading Wire is coming from the primary side of the HV transformers and looping through the black plastic current trans former on the main control board and back to the HV transformers 4 Press and hold the MGTRON soft key on the keypad to energize the magnetrons 5 Observe the amperage on the meter Typical readings are NORTH AMERICA 12 14 amps at 240VAC 13 16 amps at 208VAC INTERNATIONAL 12 15 amps at 230VAC BRAZIL 12 15 amps at 220VAC D JAPAN 16 17 amps at 200VAC If proper amperage appears but takes longer than 2 complete seconds to appear call TurboChef Tech support for assistance If amperage is present but lower than typical readings perform the troubleshooting steps in the previous pages of this section If amperage is not present check the condi tion of the F3 fuse Fuse must be a 20 amp fuse and is the right most of the three fuses on the bottom of the oven If fuse has failed replace the fuse after troubleshooting previous pages of this section If fuse has not failed check the incoming primary side voltage to the high voltage transformers THE MICROWAVE SYSTEM ISSUE RESOLUTION F3 Magnetron Current Low cont WARNING Never try to check the secondary voltages of the High Voltage Transformers With the top cover removed safe access to the three if US oven two if International oven terminals on the top of the transformers is available NORTH
92. mocouple is open Fault is cleared when the control detects continuity on the open thermocouple circuit F8 Heat Low Fault is not logged in counter Displays during WARM UP or SELF TEST if the cook cavity tempera ture TCC fails to rise at least 14 F 7 C within a given thirty 30 seconds FAULT CODE AND DESCRIPTION WHEN ACTIVE REFER TO Warm up Idle Mode Mode Self Test F1 Blower Running Status Bad X X X X Page 22 F2 Cook Temperature Low X Page 23 F3 Magnetron Current Low X X Page 34 F4 Door Monitor Defective X Page 46 F5 Magnetron Over Temperature X X Page 28 F6 EC Temperature High X X X Page 14 F7 Thermocouple Open X X X X Page 2 F8 Heat Low X X Page 22 49 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 discov ering the F1 fault F7 and F8 faults are displayed on the primary screen and are not displayed or counted in the Fault Log NOTE All Fault codes listed in bold will terminate a cook cycle upon discovery Any fault occurring in a cook cycle will be logged in the Fault Log The Control System The Control System is comprised of the components that signal sense command and switch the oven s various components Figure 7 shows a functional diagram of all the components that make u
93. mostat High Limit 102075 38 Thermostat Magnetron 102070 21 Toggle Latch NGC 1073 30 Transformer Filament USA Korea NGC 3061 1 20 Transformer Filament Europe Asia Pacific Latin America NGC 3061 2 20 Transformer Filament Japan NGC 3061 3 20 Transformer HV USA Latin America Korea NGC 3062 1 20 Transformer HV Europe Asia Pacific NGC 3062 2 20 Transformer HV Japan NGC 3062 3 20 Washer Flat 10 102140 26 Washer Shim 102449 39 Washer Split Lock 10 102350 26 Wave Guide Front NGC 3016 20 22 Wave Guide Rear NGC 3017 20 22 Wire Magnetron 100186 21 For further information call 800 90TURBO or 1 214 379 6000 Headquarters Global Operations Six Concourse Parkway 4240 International Parkway Suite 1900 Suite 105 Atlanta Georgia 30328 Carrollton Texas 75007 678 987 1700 PHONE 214 379 6000 PHONE Accelerating the World of Cooking 678 987 1750 FAX 214 379 6085 FAX TURBOCHEF COM
94. n This product conforms to the ventilation recommendations set forth by NFPA96 using EPA202 test method Packaging All ovens are packaged in a double wall corrugated box banded to a wooden skid Power Supply North America SMART VOLTAGE SENSOR TECHNOLOGY Voltage 208 240 VAC 60 Hz 1 phase Amperage Nameplate rating 30 Amp 3 wire including ground Cordset 10 gauge 3 conductor 5 foot cordset Plug NEMA 6 30 INSTALLATION SPECIFICATIONS AND MAINTENANCE NOTE The Smart Voltage Sensor Technology does not compensate for lack of voltage or over voltage situations It is the responsibility of the owner to supply voltage to the unit according to the follow ing specifications Power Supply Europe Asia Pacific NGC EW 3 phase Voltage 400 VAC 50 Hz Wye 5 wire 3L N Ground Circuit Breaker Type D min 20 Amps NGC ED 3 phase Universal Voltage 230 VAC 50 Hz Delta 4 wire 3L Ground Circuit Breaker Type D min 30 Amps NGC UK 1 phase Voltage 230 VAC 50 Hz 3 wire 2L Ground Circuit Breaker Type D min 30 Amps Power Supply Latin America NGC BK 1 phase Voltage 220 VAC 60 Hz 3 wire 2L Ground Circuit Breaker Type D min 30 Amps Power Supply Japan NGC JD 3 phase Voltage 200 VAC 50 60 Hz Delta 4 wire 3L Ground Circuit Breaker Type D min 30 Amps NGC JK 1 phase Voltage 200 VAC 50 60 Hz 3 wire 2L Ground Circuit Breaker Type D min 30 Amps Power Supply
95. nts Important Safety Instructions General Safety Information Reducing Fire Risk Precautions to be Observed Before and During Servicing to Avoid Possible Exposure to Excessive Microwave Energy Grounding Instructions Power Cord Replacement RF Interference Considerations Chapter Installation Specifications and Maintenance Specs and Dimensions Dimensions Construction Standard Features Certifications Packaging Power Supply Domestic and Intl Electrical Specifications Power Input Delivery and Product Placement Lifting and Placing the Oven Built In Installation Installation Near Open Heat Source Oven Restraint Kit Setup and Initial Operation Setup Stacking Programming Initial Power Up Maintenance Chapter 2 Theory of Operation Theory of Operation Glossary of Common Operating Terms Chapter 3 Fault Codes To View Fault Codes Fault Code Definitions Fault Code Table Chapter 4 The Control System Control System Schematic Control System Component Descriptions Test Mode Test Function Options Status Indicators 1 N RR RRR 11 11 13 14 14 15 16 Oven Options User Configurable Options Enable Disable Codes User Configurable Options Access Codes Control System Panel Parts Control System Troubleshooting Chapter 5 The Microwave System Voltage Doubler Circuit Description Monitor Circuit Description Voltage Doubler Theory of Operation Microwave Syst
96. old wave guide cover and discard unless otherwise specified NOTE It may be necessary to gently pry the wave guide covers to remove them from the oven floor as they are sealed with RTV 30 THE MICROWAVE SYSTEM 4 Using acetone clean the oven floor where the new wave guide cover will sit Apply 1 8 diameter bead of high temperature RTV included with Item 29 along the outside edge of the wave guide cover flanges NOTE It is important to use the correct high temperature as supplied by TurboChef 6 Place the new wave guide cover in place Secure with the fourteen 14 screws provided with Item 29 7 Wait 15 minutes for RTV to cure 8 Warm oven to set temperature and re check the tightness of screws Tighten if necessary WARNING Inside of oven and IR element are HOT Use extreme caution during step 8 WAVE GUIDE WAVE GUIDE COVER PARTS Figure 22 29 NGC 3036 Kit Wave Guide Cover Includes Item 31 and sealant 30 101666 Screws 28 32 x 1 2 31 101701 Screws 48 SST 32 NGC 1047 Support Frame 33 102809 Screws 8 32 x 3 8 CSK 100 34 NGC 3017 Assy Wave Guide Rear 35 NGC 3015 Magnetron Rear 36 NGC 3015 Magnetron Front 37 NGC 3016 Assy Wave Guide Front WAVE GUIDE REPLACEMENT 1 Remove the wave guide cover See WAVE GUIDE COVER REPLACEMENT on page 29 2 Remove the right side panel and frame support Item 32 3 If replacing the front wave guide
97. on the flange When it strikes the toggle latch it should rotate smoothly to its closed position Actuator doesn t clear slot Bend or adjust actuator If the actuator is worn or has yielded replace the actuator Toggle doesn t rotate freely or smoothly Replace any worn parts Clean assembly and re lubricate all rotating parts Be sure to grease the torsion spring See Figure 30 o Actuator and toggle OK Check adjustment and wiring on the interlocks If adjustment is necessary see page 38 old setup or page 42 new setup for the proper adjustment procedure 2 PS Monitor switch is open old switch setup Secondary and or monitor switch is open new switch setup Verify that the door closes freely and completely Door does not close freely Remove obstructions or readjust the oven door per the instructions on page 38 o Door closes properly Readjust the monitor safety switch old switch setup secondary and monitor new switch setup per the instructions on page 38 old setup and 42 new setup The Convection Circuit The Convection Circuit provides the high temperature airflow required to brown and cook food items CONVECTION CIRCUIT COMPONENTS The following is a description of each component within the Convection Circuit and how each acts within the circuit Figure 37 below shows a block dia gram of the Convection Circuit Main Convection Heater The main convection heater is an open co
98. oz z zm m NO 2 MONITOR INTERLOCK COMMON 24VDC 4 FOR MORE DETAIL SEE FIGURE 37 3 IR ELEMENT COMMAND 2 3 PHASE SPD Fey d CONVECTION HEATER COMMAND OUT 10 0 2 ENABLE 3 MAGNETRON COOLING FAN COMMAND 4 PRIMARY SWITCH 3 200 240 STATUSOK 5 N 0 NC C 2 VACIN GROUND 6 NO M CONTROL SECONDARY SWITCH SECONDARY SWITCH BOARD INTERLOCK NC NO VOLTAGE VOLTAGE INPUT COMMON COMMON SENSOR a IR THERMOCOUPLE AE VFD ECTHERMOCOUPLE Ld DISPLAY NN NIN AQ RR NIN CCTHERMOCOUPLE feo oe so eum Vier 14 12 4 Jac 4 7 RELAY 24VDC KEYPAD 24VDC 65 66 SERVICE PARTS AND ILLUSTRATIONS FIGURE 17 CONTROL SYSTEM PANEL ENCLOSURE AND PARTS Chapter 4 The Control System Page 20 CONTROL SYSTEM PANEL PARTS Figure 17 1 NGC 1040 NGC 1209 2 102960 3 100508 Varies 4 NGC 3023 5 101954 Cover Keypad Display Std Cover Keypad Display SBK Nut 4 40 Stainless Smart Card Blank Smart Card Programmed Display Svc Kit includes Items 5 6 and 7 Spacer 1 2 Lg Aluminum oo 9 100193 100184 1110 1 1110 2 1110 3 1110 4 100506 10 10018
99. p the Control System THE CONTROL SYSTEM at the end of this manual NOTE The part numbers for each component can be located on the drawings found throughout and K2 K3 K6 RELAY RELAY RELAY RELAY US ONLY K5 K4 24VDC 24VDC 24VDC 24VDC 3 40 3 40 L 24VDC 1 24VDC 1 oz SUPPLY 25 SE 88 MONITOR SWITCH zc EE EZ NC C oz z zm 5 NO K7 MONITOR INTERLOCK RELAY COMMON 24VDC 4 FOR MORE DETAIL SEE FIGURE 37 3 aging IR ELEMENT COMMAND 2 3 PHASE ou CONVECTION HEATER COMMAND T l ou ENABLE 3 MAGNETRON COOLING FAN COMMAND 2 VACIN See 0 INTERLOCK j CONTROL SECONDARY SWITCH BO ARD SECONDARY SWITCH INTERLOCK NC NO VOLTAGE VOLTAGE INPUT COMMON COMMON SENSOR U S ONLY AQ ji ii IR THERMOCOUPLE 1 me AQ ECTHERMOCOUPLE DISPLAY AQ aa NN NIN CC THERMOCOUPLE lt C EEE oe Se i2 ee 4 12 4 jg KEYPAD FIGURE 7 NGC Tornado Control System I3 THE CONTROL SYSTEM CONTROL SYSTEM COMPONENT DESCRIPTIO
100. r Page 52 aN IR Element and Catalytic Converter Parts 116 101312 117 102449 118 NGC 3003 119 NGC 1116 120 101688 Snap Ring Washer Shim IR Element Shield Microwave Screw 8 x 1 2 Sht Metal PTH Wire Harness Replacement P N Low Voltage Harness 123 100185 NGC 1418 Old Switch Setup New Switch Setup Line Voltage Harness 124 NGC 1150 1 North America NGC 1150 2 UK Ireland Brazil NGC 1150 3 Eu Asia Pacific Au Japan Magnetron Wire 125 100186 All NGC Ovens 121 NGC 1030 NGC 1233 122 NGC 1012 Power Cord 126 100187 100194 100195 103187 103195 NGC 1383 NGC 1390 Clip Catalytic Converter Non SBK Clip Catalytic Converter SBK Catalytic Converter USA NGC ED Europe Asia Pacific UK Ireland Brazil NGC EW Europe Asia Pacific Australia Japan 3Ph Japan 1Ph SERVICE PARTS AND ILLUSTRATIONS 77 FIGURE 46 COVERS AND MISCELLANEOUS PARTS NON SBK OVENS Covers and Miscellaneous Parts Non SBK 127 NGC 1069 1 128 NGC 1069 2 129 NGC 1068 130 102752 131 101688 132 102921 133 NGC 1071 2 134 100785 100781 135 101191 136 NGC 1054 1 NGC 1054 2 137 NGC 1064 1 Cover Left Side Cover Right Side Cover Top Screw 8 16 TORX HD Security Screw 8 Serrated Phillips TRHD CRES Screw 8 32 x 3 8 PPHD SEM Int Tooth SS Cover Bottom Front L
101. r Item 47 clears the slot in the flange Reference Figure 29 The actuator must not hang or rub the opening or flange Carefully bend to clear opening While the oven door is closed verify that the bottom of the toggle is 85 to the bottom of the frame Figure 29 If not use items 75 and 76 page 42 to achieve proper angle Temporarily adjust the primary and secondary interlock switches by loosening the 8 32 screw Item 49 and the two 2 4 40 screws Item 50 Figure 29 Rotate the interlock switches Item 51 until the gap between the switch paddles and the switch body is 0 02 0 5mm Figure 29 Restore power to the oven Allow the oven to warm to its set temperature Allow the oven to remain at the set temperature for ten 10 minutes after warm up before making any final adjustments which may be needed THE OVEN DOOR n c 3 ES XU AM f RII ges f za i e Br uu E f AES M eS Ss e ES l i Hl 3 M e SVS I III Ss E Hl SS I R E 7 _ FIGURE 28 Mis adjusted Oven Door because the door can move as a result of temper ature change 9 Securely tighten Items 49 and 50 after any final adjustments have been made 10 Complete the steps for measuring RF leakage found on page 31 Make further adjustments if
102. ree primary functions 1 To protect the operator from the hot convection airflow 2 To protect the operator from exposure to microwave energy 3 To actuate the interlock switches REMOVING REINSTALLING THE OVEN DOOR To remove or reinstall the oven door follow the steps below Refer to Figure 26 1 Ensure the oven has cooled 2 the oven door to its full open position Locate the two 2 thru holes in the bottom of the left and right hinge assemblies Insert a screw or nail into the holes to keep the hinges open while removing the oven door FIGURE 26 Oven Door Removal amp Parts THE OVEN DOOR 37 3 Locate and remove the 38 screws 3 each side 4 Remove the plastic caps NOTE The 10x32 screws do not need to be removed as they are used for adjusting the door 5 Remove the oven door by pulling the door away from the oven It will slide off the hinges OVEN DOOR PARTS Figure 26 38 102809 8 32 x 3 8 5 39 NGC 3067 Assy Oven Door Traditional NGC 3067 2 Assy Oven Door SBK 40 NGC 1061 Hinge Block 41 102804 Right Hinge 42 102805 Left Hinge 43 101381 10 32 x 1 2 Hex SS 44 102140 10 Flat 45 102350 10 Split Lock 46 101191 Cap Hole 38 THE OVEN DOOR ADJUSTING THE OVEN DOOR WARNING Procedure should be done while oven is hot As a result exercise extreme caution when adjusting the door 1 Open the oven door and remove
103. res into the cavity and through the mounting holes EI r CAUTION Do not allow the thermocouple lead wires to kink They are solid wire and will break Qo Once the IR element is installed expand the IR element in order to reinstall the shim washers Item 117 and snap rings Item 116 Figure 39 NOTE Be sure that the snap rings sit in the grooves on IR element Reconnect the IR element lead wires to the EMI filter and the high limit thermostat 5 Reconnect the IR thermocouple lead wires to the thermocouple extension wires Yellow to Yellow and Red to Red IR ELEMENT AND CATALYTIC CONVERTER PARTS Figure 39 116 101312 Snap Ring 117 102449 Washer Shim 118 NGC 3003 IR Element 119 NGC 1116 Shield Microwave 120 101688 Screw 8 x 1 2 Sht Metal PTH 121 NGC 1030 Clip Catalytic Converter Non SBK NGC 1233 Clip Catalytic Converter SBK 122 NGC 1012 Catalytic Converter Schematics and Schematic Components FIGURES 40 THRU 45 NGC OVEN SCHEMATICS Figure 40 Board Schematic Figure 41 NGC US Schematic Figure 42 NGC UK Schematic Figure 43 NGC EW Schematic Figure 44 NGC ED Schematic Figure 45 NGC Brazil Schematic SCHEMATIC PARTS Line Voltage Components Capacitor High Voltage C1 Capacitor High Voltage C2 Controller Motor Diode High Voltage D1 Diode High Voltage D2 EMI Filter P N 100
104. sformer Follow troubleshooting on page 33 to determine cause of failure b HV capacitor shorted or failing follow troubleshooting on page 33 If necessary unplug the oven and replace the HV capacitor NOTE failing HV capacitor will typically cause the HV transformer that supplies power to the failing capacitor to draw excessive current which may open the F3 fuse 35 THE MICROWAVE SYSTEM ISSUE RESOLUTION F3 Fuse Blown cont c Monitor circuit fault Verify operation of all interlock switches In addition check the Fault Log If the monitor switch opened prior to the primary and secondary the control would have recorded the occurrence See page 25 as well as Chapter 6 Oven Door for troubleshooting see F4 MONITOR Mag 1 or Mag 2 Not Working or Food Not Cooking Evenly Determine which magnetron is not oscillating by placing a clamp on amp meter on the primary winding of each high voltage transformer and energizing the Microwave System 1 Amp 0 High voltage transformer not energizing Check K2 relay and wiring going to suspect high voltage transformer K2 relay or wiring bad Replace K2 relay and or repair wiring K2 relay OK Check high voltage transformer See the table on page 33 for resistance values Unplug the oven and replace high voltage transformer if defective 2 Amps 3 amps on high voltage transformer Magnetron is not oscillating but high voltage transformer is energizing
105. tatus indicator is highlighted backlit the item or component is in an un energized or off state Conversely if a status indicator is not highlighted the component is in an energized or on state PROGRAMMING Edit Mode The EDIT MODE enables the operator to manually alter recipes and the cook cavity temperature CCSP To access EDIT MODE 1 Simultaneously press the UP and DOWN keys 2 When prompted enter the access code 9 and then press the ENTER key NOTE If this does not provide access refer to page 19 for enable disable codes Changing the Cook Chamber Temperature This temperature is a factory setting exercise caution before altering it For best results consult the factory before changing this value THE CONTROL SYSTEM EDIT GROUPS GROUP A GROUP E GROUP D GROUP H lt GOP1 gt ITEM 1 COUNT 0 COOK TIME 00 00 IR SETPT 500 F AIR 1 XXX 2 XXX 3 XXX 4 XXX 5 XXX 6 XXX TEST FIGURE 11 Select Group To change the cook cavity temperature press the UP and DOWN keys Temperature ranges vary depending on software Once you have selected the correct temperature press the ENTER key to con firm and advance to the next screen Altering a Recipe Most NGC Tornado oven models contain 128 unique recipes The display shows two 2 pages each with eight 8 recipe groups Each recipe group con tains eight 8 recipes See Figures 11 and 1
106. the plastic caps 2 Ensure that the 3 screws on each side of the door are tight 3 Remove the control panel two 35 nuts and wiring from I O board Loosen the hex screws and close the door Tap the center of the door to allow door and frame to align properly 6 Tighten screws and reinstall the control panel 7 Plug in the oven and perform a MW leak test see page 31 for instructions Critical Adjustment Notes 1 The doors in Figures 27 and 28 are adjusted incorrectly Note how the bottom Figure 27 and top Figure 28 of the door can be rotated away from the Flange CORRECTIVE ACTION Loosen the hex screws and push the door towards the flange and re tighten The hinge springs will naturally pull the door to the flange Tapping the center ensures a level surface and a proper seal as opposed to pushing one end which could cause the opposite end to lift away from the flange Pull the door open only 0 25 6 mm and let go of the handle The door must completely snap shut on its own If the door sticks and force is needed to finish closing it it is out of adjustment NOTE See Figure 26 page 37 Items 43 46 for illus tration of hardware WARNING Check for excessive Microwave Leakage after adjusting the Cook Door See page 31 for proper procedure PREPARING THE OVEN FOR SWITCH ADJUSTMENT 1 Disconnect the power to the oven and remove left and right side covers 2 Ens
107. to begin the test cook 6 Once satisfied with the recipe press SAVE to permanently store changes 7 Press the BACK key until exited from EDIT MODE THE CONTROL SYSTEM Loading a Menu from a Smart Card 1 Ensure the oven is in the OVEN OFF COOLING DOWN mode Enable the LOAD MENU function page 19 The oven will return to the Off screen Remove the lower access panel Figure 14 Insert smart card into oven Figure 14 Press the bottom left soft key Select LOAD MENU FROM CARD The menu on the smart card will load to the oven When this process completes the oven will beep Remove the smart card and reattach the lower access panel If the oven is a Subway oven disable the LOAD MENU function page 19 For all other ovens leave it enabled OVEN OPTIONS Done Screen To enable disable the Done Screen Figure 15 see the next page Enable the Done Screen to Cook item longer after the end of a cook cycle Save an adjusted cook time only if Time Screen is also enabled Time Screen To enable disable the Time Screen Figure 16 see the next page Enable the Time Screen to Adjust the cook time before initiating a cook cycle Save an adjusted cook time Snooze Mode To enable disable the Snooze Screen see the next page Enabling the Snooze Screen will allow the oper ator to set the oven in a mode during which all oven operations are turned off but the heaters
108. total number of cook counts for all recipes Press again to display the total amount of time the oven has been in cook cycles ACCUM Screen 2 Press once to display the total amount of time the magnetrons have been on Press again to display the total amount of time the oven has been on Electronic Compartment Temperature Screen 2 The ELEC key displays the temperature inside the electronic compartment F C Screen 2 Changes how the oven s temperature units are dis played The F C key alternately selects Fahrenheit or Celsius IR SI Screen 2 Displays the idle IR set point This temperature is a factory setting and should never be altered If an incorrect temperature has been entered consult the factory before changing this value STATUS INDICATORS See Figures 9 and 10 on page 15 P Primary switch closed or open S Secondary switch closed or open M Monitor switch closed or open t Magnetron thermostats closed or open h Main convection heater off or on i element off or on A Blower motor controller enabled or disabled W Microwave current Less than or greater than 7 Amps Microwave W status indicator is not highlighted backlit when the current is more than 7 Amps Status indicators are displayed at the bottom of the display screen when the oven is in TEST MODE or during normal oven operation if in DIAGNOSTIC MODE DIAG was turned on Refer to Figures 9 and 10 If a s
109. uilt In Installation Figure 2 TurboChef ovens are designed to be installed on a countertop or table They are not intended for built in or enclosed installation Built in or enclosed installation is defined as installing an oven in any structure that surrounds the oven by five sides i e top rear side panels and base INSTALLATION SPECIFICATIONS AND MAINTENANCE 2 0 51mm 2 0 51mm Unobstructed Airflow oo 300 CFM 8 5 CMM oL 1o Discharge c 3 2 e to Ambient 102 Unobstructed 2 Airflow 2 0 51mm 2 0 51mm Notes 1 Must be included by contractor FIGURE 2 Built in Installation Specs mi mr ARTITI TER T TABLE a ARTITI T 84 mm A E TER FRYE T HEF E IL mr mr FIGURE 3 Open Heat Source Installation Specs If installation must be built in the operator must D Verify oven location has a minimum 6 152 mm ensure the following Minimum of 300 cfm 8 5 cmm of supplement flow within the cabinet Minimum clearances of 2 51 mm to every surface In addition the operator will be responsi
110. ure oven door assembly is properly adjusted and all mounting screws are secured see previous section on adjusting the oven door 3 Ensure the left and right hinge assemblies are properly mounted to the oven flange Oven Burn In Procedure If the oven is already at its set temperature at the time of service skip this procedure 1 Apply power to oven 2 Simultaneously press the BACK and ENTER keys 3 Enter 8 6 4 8 U N I T then press ENTER 4 Press BURN IN The oven will warm up and idle for 25 minutes ADJUSTING THE PRIMARY AND SECONDARY INTERLOCK SWITCHES OLD SWITCH SETUP The old switch assembly is identifiable by the pri mary and secondary interlock switches being located on the left side of the oven Also the serial number of the oven will follow the formatting below X variable digit letter NGC XXXXX North America NGCXX XXXXX International To properly adjust the switches follow the proce dure below 1 Ensure the oven door is adjusted properly Refer to the previous section on adjusting the oven door 2 Unplug the oven oo il WS Ii i il d IM IM 181 IN I m LEN 4 6916 E js 7 p d ol I ES VOD FIGURE 27 Mis adjusted Oven Door Open and close the door several times to ensure it closes smoothly and the door actuato
111. ut 5VDC is not present on the I O control board J3 connector Replace I O control board Check all connections between the I O control board and display Correct any loose connections If connections are OK and 5 VDC is present on the J3 connector but there is still no display replace display No Keypad Input Check keypad ribbon cable going to the I O control board o Cable and connection bad Replace keypad o Cable and connection OK Replace the I O control board F7 Thermocouple Open CC Thermocouple Reads 999 F C or IR Thermocouple Reads 1999 F C Check the connection of open thermocouple on the I O control board If the connection is OK verify thermocouple is not an open circuit by using your ohm meter The cook cavity thermocouple should measure approximately 4 5 ohms and the IR thermocouple should measure approximately 30 40 ohms Measure at the I O control board 40 pin connector Thermocouple indicates open circuit Replace defective thermocouple Thermocouple OK Replace the I O control board NOTE F7 fault is not logged in the fault counter 21 22 THE CONTROL SYSTEM ISSUE RESOLUTION F1 Blower Running Status Bad Motor not running when commanded 1 Status Indicator A is highlighted backlit in TEST MODE Verify 208 or 240 USA 230 Intl 200 Japan 220 Latin America VAC is going to the motor controller via pins 2 and 3 208 24
112. ven door 4 With the toggle correctly adjusted and the door closed adjust the primary switch by loosening the two 4 40 screws and 78 32 screw 5 Using a 0 030 0 762 mm spacer as a template included with Item 74 adjust switch lever position to a maximum allowable distance of 0 030 0 762 mm 6 Open and close the door several times to verify the switch gap PRIMARY SWITCH ADJUSTMENT AND PARTS Figure 32 70 102809 Screw 48 32 x 3 8 100P CSK 71 102921 Screw 48 32 x 3 8 72 101555 Screw 44 40 x 3 4 73 102012 Interlock Switch 74 NGC 3033 Assy Door Switch 75 Adjustment Tools included with Item 74 NGC 1215 Door Switch Gauge NGC 1340 Shim Tool 0 060 NGC 1344 Shim Tool 0 030 76 NGC 1169 1 Shim 0 030 NGC 1169 2 Shim 0 045 Refer to FSB 10057 included with Item 74 for instructions on converting NGC 3033 kit into the new switch assembly Assembly Notes m of toggle must be within window notch Optimal is centered or below centered when the oven is hot 2 Tip of toggle adjustment notch Toggle must be within notch when oven is hot 3 If toggle hangs in position as shown decrease number of shims FIGURE 33 Secondary Monitor Adjustment and Parts New Switch Setup ADJUSTING THE SECONDARY

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