TurboChef G5 Service Manual

TM
Service Manual
   GTM   
©2013 TurboChef Technologies, Inc.
For further information, call
800.90TURBO or
+1 214.379.6000
The information contained in this manual is important for the proper installation, use, maintenance, and repair of this oven. Follow these procedures and instructions to help ensure satisfactory baking results and years of trouble-free service.
Errors – descriptive, typographic, or pictorial – are subject to correction. Specifications are subject to change without notice.
Please carefully read this manual and retain it for future reference.
Table of Contents
Important Safety Instructions
General Safety Information i Reducing Fire Risk i Grounding Instructions ii Power Cord Replacement ii Precautions to Avoid Possible Exposure to Excessive Microwave Energy ii RF Interference Considerations ii
Specifications and Installation
Theory of Operation 1 Dimensions 1 Certifications 2 Oven Construction 2 Electrical Specifications 2 Installation 2 Unpacking Instructions 2 Installing the Oven 2 Installation Near Open Heat Source 3 ChefComm Pro® 4 ChefComm LimitedTM 4 Voltage Selection 4 Ventilation 4
Daily Maintenance 5-6
Oven Modes
Manual Cook Mode 7 Menu Cook Mode 8
Menu Edit Mode 10 Edit Menu Name 11 Edit Menu Temperature 11 Edit Category Name 12 Edit Category Icon 13 View Edit Recipe Screen 14-15
Continued on next page...
Edit Recipe Cook Time 16 Edit Fan Reverse Time 16 Edit Recipe Icon 17 Edit Recipe Name 17 Run a Test Cook Cycle 18 Manager Mode 19 Set Calendar and Time 20 Set Fahrenheit/Celsius 21 Set Language to English/French 21 Set Speaker Volume 22 Access “Menu Edit Mode” 22 Set Oven Parameters 23 Set Oven Options 24 Manage Menu Data 25 Update UI Firmware 26 Update IO Firmware 26
Service Mode 27
Digital Outputs 28
Oven System
Convection System 29 Blower Motor 29 Blower Motor Speed Controller (BMSC) 29 Convection Heater 29 High Limit Thermostat 29 RTD 29 Solid State Relay 30 Troubleshooting 30 Oven Door 31 Replacing the Oven Door 31 Adjusting the Oven Door 31 Interlock Switches 32 Relay - K5 Monitor 32 Relay - K6 Primary 32 Relay - K7 Secondary 32 Measuring RF Leakage for Microwave Safety 33 Troubleshooting 33 Microwave System 34 Capacitors 34 Testing a Capacitor 34 Fuses 34 High-Voltage Transformers 34
Wiring the High-Voltage Transformers 35 Testing a High-Voltage Transformer 35 High-Voltage Diodes 36 Testing a High-Voltage Diode 36 Magnetrons 36 Magnetron Cooling Fans 36 Magnetron Thermostats 36 Testing a Magnetron for an Open/Shorted Filament 36 Relay - K2, K3, K4 Anode 37 Relay - K8 Magnetron Cooling Fans 37 Tri-Amp Board 37 Waveguides 37 Troubleshooting 37 Control System 38 User Interface 38 Relay I/O Board 38 Speaker 38 USB Port 38 Troubleshooting 38 Electrical Components 39 Circuit Breaker 39 Electrical Compartment Cooling Fan 39 Electrical Compartment Cooling Fan Thermostat 39 EMI Filter 39 Power Supply 39 Relay - K1 Voltage 39 Voltage Transformer 39 Wire Harness 39 Troubleshooting 39
Troubleshooting
Overview of Troubleshooting 41 Fault Code Descriptions 41 F1: Blower Running Status Bad 43 F2: Cook Temperature Low 44 F3: Magnetron Current Low 45 F4: Door Monitor Defective 46 F5: Magnetron Over Temperature 47 F8: Heat Low 48
Continued on next page...
“Oven Door Open” Message when Door is Closed 49 Cooling Verification 50 Inconsistent/Inaccurate Temperature Readings 50 No Display - Screen is Blank 51 No Display - Screen is Blinking or Resetting 51 Food Not Cooking Properly 52
Oven Schematic
U.S. and Canada 54-59 International 60-65
Appendix
Replacing Oven Components A-1 Oven Exterior A-2 Convection System A-4 Oven Door and Related Parts A-6 Microwave System A-8 Controls System A-10 Electrical System A-12
IMPORTANT SAFETY INSTRUCTIONS
WARNING: When operating this oven, strictly adhere to the following safety precautions to reduce the risk of burns, electric shock, fire, injury, damage to oven or property near oven, or possible exposure to excessive microwave energy.
GENERAL SAFETY INFORMATION
a
Read all instructions before using this appliance.
a
Read and follow the specific “Precautions to be Observed Before and During Servicing to Avoid
Possible Exposure to Excessive Microwave Energy” found on page ii.
a
This appliance must be grounded. Connect only to a properly grounded outlet. See “Grounding
Instructions” on page ii.
a
Install or locate this appliance only in accordance with the provided installation instructions.
a
This appliance should be serviced by qualified service personnel only. Contact the nearest
authorized service facility for examination, repair, or adjustment.
a
Keep the cord away from heated surfaces.
a
Liquids, such as water, coffee, or tea are able to be overheated beyond the boiling point without appearing to be boiling. Visible bubbling or boiling when the container is removed from the microwave oven is not always present.                       .
a
: The contents of feeding bottles and baby food jars must be stirred or shaken and the temperature checked before consumption, in order to avoid burns (IEC 60335-2-90).
a
Use this appliance only for its intended uses as described in this manual.
a
Only use utensils that are suitable for use in microwave ovens (IEC 60335-2-90).
a
  use corrosive chemicals or vapors in this appliance; it is not designed for industrial/laboratory use.
X
:   heat liquids or other foods in sealed containers (e.g., jars, whole eggs, etc.) since they are liable to explode.
X
  allow children to use this appliance.
X
  operate this appliance if it has a damaged cord or plug, is not working properly, or has been damaged or dropped. See “Power Cord Replacement” found on page ii.
X
  cover or block any openings on this appliance.
X
  store this appliance outdoors.
X
  use this product near water (e.g., near a kitchen sink, in a wet basement, near a swimming pool).
X
  immerse the cord or plug in water.
X
  let the cord hang over the edge of a table or counter.
X
  use a water jet for cleaning. See pages 5-6 in this manual for proper cleaning procedures.
X
This appliance is not to be used by children or persons with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction.
i
REDUCING FIRE RISK
a
Remove wire twist-ties from paper or plastic bags used to facilitate cooking in the oven.
a
If materials inside the oven ignite, keep the oven door closed, turn the oven off, and disconnect the power cord or shut off power at the fuse or circuit breaker panel.
a
If smoke is observed, switch off or unplug the oven. Keep the door closed to stifle any flames.
X
  use the cook cavity for storage purposes.
X
  overcook food. Carefully attend to the oven if paper, plastic, or other combustible materials are placed inside the oven to facilitate cooking.
X
  leave paper products, cooking utensils, or food in the cavity when the oven is not in use.
SAVE THESE INSTRUCTIONS
SAFETY INSTRUCTIONS
ii SAFETY INSTRUCTIONS
GROUNDING INSTRUCTIONS
This appliance must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. This oven is equipped with a cord that has a grounding wire with a grounding plug, which must be plugged into an outlet that is properly installed and grounded. Consult a qualified electrician or serviceman if uncertain about the ability to follow grounding instructions or if doubt exists as to whether the appliance is properly grounded.
X
  use an extension cord. If the power cord is too short, have a qualified electrician or
service agent install an outlet near the appliance.
WARNING: Improper grounding can result in risk of electric shock.
POWER CORD REPLACEMENT
If the power cord is damaged, it must be replaced by the manufacturer, its service agent, or a similarly qualified person.
PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY
(a) Do not operate or allow the oven to be operated with the door open. (b) Make the following safety checks on all ovens to be serviced before activating the magnetron or other microwave source, and make repairs as necessary: (1) interlock operation, (2) proper door closing, (3) seal and sealing surfaces (arcing, wear, and other damage), (4) damage to or loosening of hinges and latches, (5) evidence of dropping or abuse. (c) Before turning on microwave power for any service test or inspection within the microwave generating compartments, check the magnetron, wave guide or transmission line, and cavity for proper alignment, integrity, and connections. (d) Any defective or misadjusted components in the interlock, monitor, door seal, and microwave generation and transmission systems shall be repaired, replaced, or adjusted by procedures described in this manual before the oven is released to the owner. (e) A microwave leakage check to verify compliance with the Federal Performance Standard should be performed on each oven prior to release to the owner. Refer to page 33 for leakage test procedures.
RF INTERFERENCE CONSIDERATIONS
The G5 oven generates radio frequency signals. This device has been tested and was determined to be in compliance with applicable portions of FCC part 18 requirements and to the protection requirements of Council Directive 89/336/EEC on the approximation of the laws of the Member States relating to 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:
a
Increase the physical separation between this oven and the sensitive equipment.
a
If the sensitive device can be grounded, do so following accepted grounding practices.
a
If battery-powered microphones are being affected, ensure that the batteries are fully charged.
a
Keep sensitive equipment on separate electrical circuits if possible.
a
Route intercom wires, microphone wires, speaker cables, etc. away from the oven.
SAVE THESE INSTRUCTIONS
Specifications and
Installation
1
55.29”
(1404 mm)
32.29”
(820 mm)
32.29”
(820 mm)
23”
(584 mm)
G5 Oven Dimensions
30.08”
(764 mm)
Theory of Operation
The TurboChef G5 oven maximizes throughput by cooking up to five shelves of food without compromising quality. Variable G5 cooking features include temperature selection, high-speed air convection, fan reverse, and microwave assist.
This manual includes instructions for installing, cleaning, and operating the G5 oven. If you have questions that are not addressed in this manual, contact Customer Support at 800.90TURBO (USA) or +1 214.379.6000 (International), or your Authorized Distributor.
38.12” (968 mm)
31.24” (793 mm)
35.70” (907 mm)
Dimensions
Oven Dimensions
Height: 32.29” (820 mm) Height with cart: 55.29” (1404 mm) Width: 31.24” (793 mm) Depth (footprint): 35.70” (907 mm) Depth (door closed): 38.12” (968 mm) Depth (door open): 57.12” (1451 mm) Weight: 475 lb. (215 kg)
Cook Cavity Dimensions - Overall
Height: min: 3.25” (83 mm) per shelf max: 18” (457 mm) Width: 15” (381 mm) Depth: 21” (533 mm) Volume: min: 0.59 ft3 (16.7 l) per shelf max: 3.28 ft3 (92.88 l)
SPECIFICATIONS AND INSTALLATION
Cooking Rack
Width: 14.6” (371 mm) Depth: 18.1” (460 mm) Max food height: 17” (432 mm)
Wall Clearance
Top: 2” (51 mm) Sides: 2” (51 mm)
2 SPECIFICATIONS AND INSTALLATION
Certifications
cULus, UL EPH, FDA, TÜV
Oven Construction
Exterior
- 304 stainless steel side panels
- 430 stainless steel door
- Single-stage, locking door handle
Interior
- 316 stainless steel
- Welded and insulated cook chamber
- Removable baffle for easy cleaning
Electrical Specifications
TurboChef recommends a Type D circuit breaker for all installations outside the United States.
Installation
Install or locate this appliance only in accordance with the instructions below.
Unpacking Instructions
1. Remove the oven from its packaging.
2. Before throwing the packaging away, check it thoroughly for accessories and literature.
NOTE: Keeping the packaging is recommended in case the oven may be shipped to another location.
3. Check the cook cavity thoroughly for packaging, accessories, and oven literature.
Installing the Oven
1. The TurboChef G5 is mounted to a cart at the factory and shipped secured to the cart. Minimal to no lifting should be required.
WARNING: The oven weighs approximately 475 lb. (215 kg). If lifting is required, to prevent serious injury, at least four people are required for lifting.
2. Ensure the oven racks are properly installed.
3. Plug in the oven.
United States/Canada
Phase and voltage: 3 Phase, 208/240 VAC Frequency: 50/60 Hz Current draw: 42-45 Amp Cord and plug: 4-Wire, NEMA 15-50P Fuses: 20 Amp Aux Breaker: 20 Amp
International
Phase and voltage: 3 Phase, 380-415 VAC Frequency: 50 Hz Current draw: 25-28 Amp Cord and plug: 5-Wire, WYE (32A - 6H) Fuses: 12 Amp Aux Breaker: 20 Amp
* US/Canada models include a voltage transformer located on the I/O relay board that detects 208 or 240 VAC. The voltage transformer and K1 voltage selection relay work in conjunction to detect lack-of or over-voltage installations. They do not compensate for lack-of or over-voltage installations.
CAUTION: This oven is not intended for built-in installation (i.e., installing the oven in any structure that surrounds the oven by five or more sides). Be sure to provide a minimum of 2” (51 mm) clearance for all surfaces.
WARNING: Do not attempt to stack this oven without the proper stacking hardware. Contact the factory for more information.
Installation Near Open Heat Source
Minimum
Minimum
When placing a TurboChef oven near an open heat source (see illustration below), strictly adhere to the following:
- If the oven is being placed near a grill or stove, a divider must exist between the oven and the open heat source, with a minimum of 6” (152 mm) between the oven and the divider.
- If the oven is being placed near a fryer, a divider must exist between the oven and fryer, with a minimum of 12” (305 mm) between the oven and the divider.
- The height of the divider must be greater than or equal to the height of the oven (32.3” or 820 mm).
- Verify the oven location has a minimum 2” (51 mm) clearance on the top and each side.
3
Partition
32.3” (820 mm) Above Counter Top
Grill
Installation Near Open Heat Source
6”
(152 mm)
TurboChef
G5 Oven
Cart / Stand
12”
(305 mm)
Partition
32.3” (820 mm) Above Counter Top
Deep Fryer
SPECIFICATIONS AND INSTALLATION
4 SPECIFICATIONS AND INSTALLATIONSPECIFICATIONS AND INSTALLATION
ChefComm Pro
Part Number: CON-7006
ChefComm Pro® lets you easily create menu settings on a computer and upload them to an oven via USB thumb drive. For more information, call TurboChef Customer Support at 800.90TURBO or +1 214.379.6000.
ChefComm Limited
Part Number: CON-7016
ChefComm LimitedTM is a “read-and-transfer only” version of ChefComm Pro that helps ensure menu settings are easy to distribute, while preventing them from being changed at the store level.
Voltage Selection
For US/Canada oven models, the oven will detect 208 or 240 incoming voltage.
If incoming voltage for the store is different than the factory-preset voltage, the operator will be required to select either 208 or 240 after connecting power to the oven. The correct voltage will be enlarged on the screen, identifying which option to select.
Ventilation
The TurboChef G5 oven must be installed under a ventilation hood, in accordance with local HVAC codes and jurisdictions.
Daily Maintenance
5
08:35
Daily Maintenance
Follow the steps below when cleaning the G5 oven.
1
TOOLS
2
POWER
Status
Door
Closed
Status O = Ready to Clean
Select option
Off
Step 1: Cool the Oven
WARNING: e oven operates at temperatures up to 550°F (288°C) and may cause injury if not allowed to cool properly.
• Turn o the oven by touching “ESC” until the main power screen returns.
• Slightly open the oven door.
• Cooling takes approximately 40 minutes.
DO NOT clean the oven until the display reads “Status O.”
Step 2: Remove the Wire Racks
Supplies and Equipment
TurboChef ® Oven Cleaner (Product #: 103180), TurboChef ® Oven Guard (Product #: 103181), nylon scrub pad, cleaning towel, disposable gloves, protective eyewear, dust mask (optional)
3
Step 3: Remove Large Food Particles
• Use a vacuum hose or damp towel.
4
Do Not
Spray this
Area
Step 4: Spray Stains with Oven Cleaner
• Spray cleaner onto stains/debris build-up and allow it to set for ve minutes.
DO NOT spray cleaner near the heater elements or convection fan blade.
DAILY MAINTENANCE
5
Step 5: Scrub Stains
• Scrub stains with a nylon scrub pad.
Continued on page 6...
6 DAILY MAINTENANCE
6
Step 6: Wipe the Oven Cavity
• Wipe the oven cavity and door with a damp towel to collect any remaining cleaner residue.
• oroughly dry the cavity and door with a dry towel.
7
Step 7: Clean the Lower Tray
• Remove the lower tray to remove large particles and clean with a damp towel.
8
Step 8: Apply TurboChef Oven Guard
• Spray TurboChef Oven Guard onto a clean towel.
• Wipe the oven’s interior walls and the inside of the oven door.
CAUTION: DO NOT spray Oven Guard directly into the cavity, as it may settle and build up on the heater elements or the convection fan blade, resulting in a non-warranty service call.
10
11
9
Step 9: Reinstall the Oven Racks
Step 10: Clean the Oven Exterior
• Wipe the oven exterior with a clean, damp towel.
CAUTION: DO NOT spray chemicals into any openings, such as the louvers on the back panel or the rear lter. Doing so can damage critical oven components, resulting in a non-warranty service call.
Step 11: Check the Rear Filter
• Remove the lter and rinse it gently in water.
• Reinstall the clean lter.
• If the lter is damaged, replace it using part number i5-9039.
• e oven is ready to turn on.
Oven Modes
- Manual Cook
- Menu Cook
- Menu Edit
- Manager
Manual Cook Mode
Manual Cook Mode allows cooking “on the fly,” whereas Menu Cook Mode (page 8) allows cooking from pre-set cook settings.
NOTE: If the Manual Mode icon is not present, see pages 19 and 24 to make it appear.
Select
135/450°F
Menu
Dinner
Lunch
If required, enter passcode 9428. See page 24 to enable/disable passcode options.
Manual Mode
Status
Heating
Oven temperature
Touch to exit Manual Mode.
Cool Down
Off /
Breakfast
Prep
Closed
Door
7
Touch to add 30 sec­onds to a shelf timer, or hold to rapidly increase shelf timer.
Touch to clear a shelf timer.
Touch to begin counting down the shelf timer.
While a shelf timer is counting down, touch to pause the shelf timer.
“Microwave Assist” note will appear after the oven has completed warming up.
Touch to set the temperature.
Touch to modify the fan speed.
Touch to modify the fan reverse time.
OVEN MODES  MANUAL COOK
Touch to set Microwave Assist to low, medium, high, or off. Microwave energizes only when the timer is set to greater than zero.
NOTE: Whenever the oven door is opened, the Microwave Assist is set to off and the microwave circuit de-energizes.
NOTE: Cook options are not available while the oven is heating up.
8 OVEN MODES  MENU COOK
Menu Cook Mode
The oven is programmed with recipe settings at the time of manufacture and is ready to operate out of the box. New menu settings can be loaded via USB (page 25) or programmed manually (page 10).
1. Turn the oven on.
4. Select an item. To view more items, touch the arrows at the top and bottom of the item list.
5. Select how many shelves of product will be cooked.
2. Select a menu, or select “Manual Mode” to enter Manual Cook Mode (see page 7 for details).
3. Select a food group. To view more groups, touch the arrow at the top of the screen.
6. The oven may require additional heating time before cooking can begin. Progress is displayed at the bottom of the screen.
7. If the oven is heating up for the first time, it may require an additional “soak” time, to ensure the cavity walls retain enough heat so that cooking performance will not be affected.
9
8. When the oven is done heating, place the food on the shelves as shown on the screen.
WARNING: Inside of oven and oven door are hot!
10. Cook the food:
a. Touch “Start Cooking.”
d. To stop cooking immediately, touch the Stop icon.
e. When cooking is done, check the food or remove it from the oven.
WARNING: Inside of oven and oven door are hot!
b. The timer will begin counting down.
c. To pause cooking, touch the Pause icon.
To resume cooking, touch the Start icon.
f. Additional options:
- Select “Cook More” if the inside of the food is not done.
- Select “Brown More” if the outside of the food needs more browning.
- Select “Cook + Brown” if both the inside and outside of the food require more cooking.
- To cook another batch of the same product, touch “Cook Another.”
- To cook something else, or to select a different number of shelves for cooking the same product, touch “Cook Something Else.”
OVEN MODES  MENU COOK
10 OVEN MODES  MENU EDIT
Menu Edit Mode
Follow the steps below to access the “Menu Edit Mode” screen. From this screen, users can:
• Edit setting names
• Set menu temperature
• Edit icons
• Edit cook settings
• Test cook
• Delete menus, categories, and items
Start Here
Enter passcode 9428.
To select a menu, touch the menu name.
NOTE: A G5 menu file consists of 12 menus, each containing 18 categories, each containing 18 items, each containing 5 shelf configurations. There are 19,440 total uniquely-programmable cooking profiles.
CAUTION: If “Delete” is selected (blue), touching a menu will delete it from the oven. In this illustration, “Edit” is selected (blue).
Edit Menu Name
11
From the “Menu Edit Mode” screen (page 10), touch the “Edit Menu Name” icon.
Displays the menu selected.
Use keypad to type new name.
Touch to access special characters. Use arrow keys to move the cursor
without deleting existing text.
Touch “Enter” to save changes.
Edit Menu Temperature
From the “Menu Edit Mode” screen (page 10), touch the “Edit Menu Temperature” icon.
OVEN MODES  MENU EDIT
Use numeric keypad to enter new temperature.
Touch “Save & Exit” to save temperature.
12 OVEN MODES  MENU EDIT
Edit Category Name
From the “Menu Edit Mode” screen (page 10), touch “Select Category” icon.
Touch a category name to access the screen below.
CAUTION: If “Delete” is selected (blue), touching a menu will delete it from the oven. In the adjacent illustration, “Edit” is selected (blue).
Touch “Edit Category Name”
Touch to save the new name.
Use keypad to type new name.
Touch to access special characters. Use arrow keys to move the cursor
without deleting existing text.
Edit Category Icon
13
From the “Menu Edit Mode” screen (page 10), touch “Select Category” icon.
Touch a category name to access the screen below.
CAUTION: If “Delete” is selected (blue), touching a menu will delete it from the oven. In the adjacent illustration, “Edit” is selected (blue).
Touch “Edit Category Icon.”
Select the name of the category.
Touch to save the new icon.
OVEN MODES  MENU EDIT
CAUTION: If “Delete” is selected (blue), touching a menu will delete it from the oven. In the adjacent illustration, “Edit” is selected (blue).
Touch an image to select it as the new category icon.
14 OVEN MODES  MENU EDIT
View Edit Recipe Screen
From the “Menu Edit Mode” screen (page 10), touch “Select Category” icon.
Touch a category name to access the screen below.
CAUTION: If “Delete” is selected (blue), touching a menu will delete it from the oven. In the adjacent illustration, “Edit” is selected (blue).
Touch “Select Item to Edit”
See adjacent page for a larger view.
CAUTION: If “Delete” is selected (blue), touching a menu will delete it from the oven. In the adjacent illustration, “Edit” is selected (blue).
Edit Recipe Screen Overview
From the “Edit Recipe Screen” users can:
• Edit recipe cook time
• Edit fan reverse time
• Edit recipe icon
• Edit recipe name
• Run a test cook cycle
15
Each food item includes up to five shelf configurations. The settings on the adjacent screen are for two shelves of product (i.e., “Shelves 2”).
NOTE: The sum of event time percentages must always equal 100. In this example, there are two events, each set to 50% of the cook time.
Touch “Save” when finished.
Events are phases of a cook cycle. Up to 6 events can be added, each with varying levels of air and microwave. Increase or decrease the amount of time for each event by changing the %Time.
OVEN MODES  MENU EDIT
NOTE: Event settings can be stored for up to 5 different shelf configurations (i.e., “shelves in use”) per item.
16 OVEN MODES  MENU EDIT
Edit Recipe Cook Time
From the “Edit Recipe” screen (pages 14-15), touch the cook time icon.
Touch to toggle between minutes and seconds (MM:SS) and hours and minutes (HH:MM).
Use numeric keypad to enter time.
Edit Fan Reverse Time
From the “Edit Recipe” screen (pages 14-15), touch the fan reverse icon.
Touch “Enter” to save time.
Use numeric keypad to input new fan reverse time.
Touch “Enter” to save new time.
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