Turbochef I5 Service Manual

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Service Manual

FOR THE TURBOCHEF® i5 RAPID COOK OVEN

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For further information, call

800.90TURBO or

+1 214.379.6000

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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.

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Safety Instructions

General Safety Information i Reducing Fire Risk i Grounding Instructions ii Power Cord Replacement ii Precautions to be Observed Before and During Servicing to Avoid

Possible Exposure to Excessive Microwave Energy ii RF Interference Considerations ii

Specifications and Installation

Theory of Operation 1 Certifications 1 Dimensions 1 Oven Construction 1 Electrical Specifications 2 Unpacking Instructions 3 Lifting and Placing the Oven 3 Installation Near Open Heat Source 4 Optional Installation Items 4 Voltage Selection 6 Ventilation Requirements 6

Daily Maintenance 7

Oven Controls and Cooking

Oven Controls 9 Cooking 10 Step 1: Turn the Oven On 10 Step 2: Select Cook Temperature 10 Step 3: Warming Up 10 Step 4: Soaking 11 Step 5: Ready to Cook or “Idle” 11 Step 6: Adjusting the Time 11 Step 7: Cooking 11 Step 8: Remove Food from Oven 12 Step 9: Additional Cooking Options 12 Step 10: Cooling Down 12

Info Mode

Overview of the Info Mode 13 Viewing Cook Counter/Time Logs 13 Viewing the Fault Log 13 Viewing the Service Numbers 14 Resetting the Oven 14

Table of Contents

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Options Screen 14 Setting the Language 14 Setting the Date/Time 14 Adjusting the Volume 14 Setting the F2 Alarm 15 Making a Copy of the Oven Menu 15 Updating the Oven Menu 15 Updating the Oven Firmware 15

Test Mode

Test Mode - Testing Oven Parts 16 Status Indicators 16 Fault Log 16 Turning Diagnostic Mode On/Off 16 Manufacturing Mode 17

Microwave Leakage Test (How to Use Oven for Testing) 17 Microwave Power Test 17 Burn-In 17 Serial Number Edit 17 Changing Temperature Measurement Setting 17 Self Test 17 Volt On 18 Erase/Default Oven Settings 18

Edit Mode

Overview of the Edit Mode 19 Changing Set Temperatures 19 Changing Food Group/Item Name 20 Changing Recipe Settings 20

Oven Systems

Convection System 21

Blower Motor (Bottom) 21 Blower Motor (Top) 21 Blower Motor Controller (BMSC) 21 Heater Element 21 Jetplate (Bottom) 21 Jetplate (Top) 21 Stirrer Motor and Assembly 21 Convection System Troubleshooting 22

Oven Door 22

Removing/Reinstalling the Oven Door 22 Adjusting the Oven Door 22 Interlock Switches 24 Adjusting the Door Switches 24 Hinges and Counter-Balance Assembly 24 Adjusting the Counter-Balance Assembly 24 Measuring RF Leakage for Microwave Safety 25 Oven Door Troubleshooting 26

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Microwave System 27

Capacitors 27 Testing a Capacitor 27 Filament Transformers 27 Wiring the Filament Transformers 27 High-Voltage Transformers 28 Wiring the High-Voltage Transformers 28 Testing a Filament or High-Voltage Transformer 28 High-Voltage Diodes 28 Testing a High-Voltage Diode 29 Magnetrons 30 Testing a Magnetron for an Open/Shorted Filament 30 Stirrer Motor and Assembly 30 Wave Guides 30 Microwave System Troubleshooting 30

Control System 31

Control Board 31 Display 31 Electrical Compartment Cooling Fans 31 Electrical Compartment Cooling Fan Thermostat 31 Electrical Compartment Thermocouple 31 EMI Filter 31 Fuses 31 High-Limit Thermostat 32 Keypad 32 Magnetron Cooling Fans 32 Magnetron Thermostats 32 Power Supply 32 Relay - K1 Filament 32 Relay - K2 Anode 32 Relay - K3 Monitor 32 Relay - K6 Voltage 32 Relay - K7 Magnetron Cooling Fan 32 Relay - K8 Stirrer Motor 32 RTD 33 Smart Card Reader 33 Solid State Relay - K4/K5 Heater 33 Speaker 33 USB Port 33 Voltage Sensor 33 Wire Harness 33 Control System Troubleshooting 33

Filtering System 34

Catalytic Converter 34 Drain Pan 34 Air Filter 34 Vent Catalyst 34 Filtering System Troubleshooting 34

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Troubleshooting

Overview of Troubleshooting 35 Fault Code Descriptions 35 Fault Code Troubleshooting - F1 Blower Running Status Bad 37 Fault Code Troubleshooting - F2 Cook Temperature Low 38 Fault Code Troubleshooting - F3 Magnetron Current Low 39 Fault Code Troubleshooting - F4 Door Monitor Defective 40 Fault Code Troubleshooting - F5 Magnetron Over Temperature 40 Fault Code Troubleshooting - F6 Electrical Compartment Temperature High 41 Fault Code Troubleshooting - F7 Open RTD 41 Fault Code Troubleshooting - F8 Heat Rise Low 42 Fault Code Troubleshooting - F9 Cook Cavity Temperature High 42 Non-Fault Code Troubleshooting - No Keypad Input 43 Non-Fault Code Troubleshooting - “Door Open” Message when Door is Closed 43 Non-Fault Code Troubleshooting - No Display (Screen is Blank) 44 Non-Fault Code Troubleshooting - Food Not Cooking Properly 45 Non-Fault Code Troubleshooting - “Read Fail” Message when Loading a Menu 46 Non-Fault Code Troubleshooting - “Write Fail” Message when Loading a Menu 47 Non-Fault Code Troubleshooting - “Defective Media” Message When Oven is

Plugged in or Restarted 48

Oven Schematic 49

Appendix - Replacing Oven Components

Comprehensive Table of Oven Components A-1 Replacing Items - No Cover Removal Required A-3 Replacing Items - Opening Top Cover Required A-5 Replacing Items - Removing Top Cover Required A-7 Replacing Items - Removing Left Side Cover Required A-9 Replacing Items - Removing Right Side Cover Required A-11 Replacing Items - Removing/Opening Multiple Covers Required A-12

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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

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Read all instructions before using this appliance.

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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.

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This appliance must be grounded. Connect only to properly grounded outlet. See "Grounding Instructions" found on page ii.

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Install or locate this appliance only in accordance with the provided installation instructions.

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Some products such as whole eggs and sealed containers (e.g., closed glass jars) may explode and should not be heated in this oven.

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Use this appliance only for its intended uses as described in this manual.

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This appliance should be serviced only by qualified service personnel. Contact the nearest authorized service facility for examination, repair, or adjustment.

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Keep cord away from heated surfaces.

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Liquids, such as water, coffee, or tea are able to be overheated beyond the boiling point without appearing to be boiling. Visible bubbling or boiling when the container is removed from the microwave oven is not always present. THIS COULD RESULT IN VERY HOT LIQUIDS SUDDENLY BOILING OVER WHEN THE CONTAINER IS DISTURBED OR A UTENSIL IS INSERTED INTO THE LIQUID.

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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.

DO NOT allow children to use this appliance. Children should be supervised to ensure that they do not

play with the 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 found on page ii.

DO NOT cover or block any openings on this appliance.

DO NOT store this appliance outdoors.

DO NOT

use this product near water (e.g., near a kitchen sink, in a wet basement, near a swimming pool).

DO NOT immerse cord or plug in water.

DO NOT let cord hang over the edge of table or counter.

DO NOT

use a water jet for cleaning. See the Maintenance section (pages 7-8) for proper cleaning

procedures.

Reducing Fire Risk

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Remove wire twist-ties from paper or plastic bags used to facilitate cooking in the oven.

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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.

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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 to 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.

SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

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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.

DO NOT

use an extension cord. If the power cord is too short, have a qualified electrician or

serviceman install an outlet near the appliance.

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 pages 25-26 for leakage test procedures.

RF Interference Considerations

The i5 oven generates radio frequency signals. This device has been tested and was determined to be in compliance with applicable portions of FCC part 18 requirements and to the protection requirements of Council Directive 89/336/EEC on the approximation of the laws of the Member States 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:

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Increase the physical separation between this oven and the sensitive equipment.

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If the sensitive device can be grounded, do so following accepted grounding practices.

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If battery-powered microphones are being affected, ensure that the batteries are fully charged.

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Keep sensitive equipment on separate electrical circuits if possible.

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Route intercom wires, microphone wires, speaker cables, etc. away from the oven.

ii SAFETY INSTRUCTIONS

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Specifications and Installation

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SPECIFICATIONS AND INSTALLATION

Theory of Operation

The i5 rapid cook oven combines preciselycontrolled impinged air and microwave energy to create higher heat transfer rates than conventional ovens. Top-launched microwave and impinged air are stirred to further ensure even heat distribution, while impinged air enters the cavity from the top and bottom, generated by dual independentlycontrolled blower motors. The combination of this technology with the size of the cook cavity allows for higher throughput than other batch ovens.

This manual includes instructions for servicing, troubleshooting, installing, cleaning, and operating the i5 oven. If you have questions that are not addressed in this manual, contact Technical Service (800.90TURBO, +1 214-379-6000) or your Authorized Distributor.

Certifications

cULus, UL EPH, TÜV, CE, FDA

Dimensions

Oven Dimensions

Height: 24.3” (618 mm) Width: 27.2” (691 mm) Depth (door closed): 28.25” (718 mm) Depth (door open): 43.4” (1102 mm) Weight: 275 lbs (125 kg)

Cook Cavity Dimensions

Height: 10” (254 mm) Width: 24” (610 mm) Depth: 16” (406 mm) Volume: 2.22 ft

(63 liters)

Clearances

Top: 16” (406 mm) Sides: 2” (51 mm)

NOTE: This oven is not stackable.

Oven Construction

Exterior

- Two-tone stainless steel front, top and sides

- 304 stainless steel removable grease pan

- Ergonomic door handle

- Rubber seal for surface mounting

- Side handles for lifting

Interior

- 304 stainless steel interior

- Fully-insulated cook chamber

- Removable rack with dual setting option

- Top and bottom jetplates

27.2”

Figure 1: i5 Oven Dimensions

(691 mm)

24.3”

(618 mm)

31.1”

(790 mm)

28.25”

(718 mm)

43.4”

(1102 mm)

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2 SPECIFICATIONS AND INSTALLATION

Multi Phase

i5 DL (USA) model (i5-9500-14-DL)*

208/240 VAC, 60 Hz, 30 Amps Max Input: 9500/11500 watts Plug: NEMA 15-30P

i5 BD model (i5-9500-16-BD)

220 VAC, 60 Hz, 28 Amps Max Input: 10000 watts Plug: IEC 309, 4-pin

i5 LD model (i5-9500-15-LD)

220 VAC, 60 Hz, 28 Amps Max Input: 10000 watts Plug: NEMA 15-30P

i5 EW model (i5-9500-4-EW)

400 VAC, 50 Hz, 19 Amps Max Input: 10000 watts Plug: IEC 309, 5-pin

i5 AU model (i5-9500-5-AU)

400 VAC, 50 Hz, 19 Amps Max Input: 10000 watts Plug: Clipsal 5-pin

i5 KW model (i5-9500-12-KW)

400 VAC, 60 Hz, 19 Amps Max Input: 10000 watts Plug: IEC 309, 5-pin

i5 ED model (i5-9500-3-ED)

230 VAC, 50 Hz, 28 Amps Max Input: 10000 watts Plug: IEC 309, 4-pin

i5 SD model (i5-9500-13-SD)

230 VAC, 60 Hz, 28 Amps Max Input: 10000 watts Plug: IEC 309, 4-pin

i5 JD model (i5-9500-9-JD) - 50 Hz

(i5-9500-11-JD) - 60 Hz

200 VAC, 50 or 60 Hz, 25 Amps Max Input: 10000 watts Plug: PSE-marked, 4-blade

Electrical Specifications

TurboChef recommends a Type D circuit breaker for all installations outside the US.

* North America models include a voltage sensor that detects 208 or 240 VAC. The voltage sensor does

not compensate for lack-of or over-voltage installations.

Single Phase

i5 US model (i5-9500-1)*

208/240 VAC, 60 Hz, 48 Amps Max Input: 9500/11500 watts Plug: NEMA 6-50P

i5 BK model (i5-9500-6-BK)

220 VAC, 60 Hz, 48 Amps Max Input: 10000 watts Plug: IEC 309, 3-pin

i5 LA model (i5-9500-7-LA)

220 VAC, 60 Hz, 48 Amps Max Input: 10000 watts Plug: NEMA 6-50P

i5 UK model (i5-9500-2-UK)

230 VAC, 50 Hz, 48 Amps Max Input: 10000 watts Plug: IEC 309, 3-pin

i5 JK model (i5-9500-8-JK) - 50 Hz

(i5-9500-10-JK) - 60 Hz

200 VAC, 50 or 60 Hz, 46 Amps Max Input: 9000 watts Plug: PSE-marked, 3-blade

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SPECIFICATIONS AND INSTALLATION

Figure 2: Hand Grip Locations

Unpacking Instructions

1. Remove oven from packaging.

2. Before discarding packaging, check thoroughly for accessories, consumables, and literature.

3. Discard packaging.

4. Check cook cavity thoroughly for accessories, consumables, and literature.

5. Discard any packaging in cook cavity.

Lifting and Placing the Oven

WARNING: Oven weighs approximately 275 lbs (125 kg). Never lift with fewer than two people.

WARNING: Lift only using the provided hand grips. Never lift the oven by the door handle or by its base.

WARNING: The oven must be properly placed on a table or countertop at all times. TurboChef will not recognize a fallen oven as a warrantable claim and is not liable for any injuries that may result.

WARNING: This oven is not intended for built-in installation (i.e., installing the oven in any structure that surrounds the oven by five or more sides). Be sure to provide a minimum of 2” (51 mm) clearance for all sides and 16” (406 mm) clearance for the top.

1. Prepare a surface that is at least 30” (762 mm) deep and capable of supporting 280 lb. (127 kg). If installing onto an oven cart, make sure the wheels/casters are locked.

2. Position one or more persons at the front and rear of the oven.

3. Place hands into grips (see Figure 2) and lift.

4. Place the oven on the prepared surface or cart, ensuring no edges are hanging off the sides.

5. Install the oven rack.

6. Plug in the oven.

NOTE: The oven is primarily serviced through its top. DO NOT install shelving directly over the unit. The operator will be responsible for service charges incurred as a result of added time required to access the top of the oven.

Install or locate this appliance only in accordance with the instructions below.

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4 SPECIFICATIONS AND INSTALLATION

Installation Near Open Heat Source

See Figure 3, page 5.

When placing a TurboChef oven near an open heat source, strictly adhere to the following:

- If the oven is being placed near a grill or stove, a divider must exist between the oven and the open heat source, with a minimum of 6” (152 mm) between the oven and the divider.

- If the oven is being placed near a fryer, a divider must exist between the oven and fryer, with a minimum of 12” (305 mm) between the oven and the divider.

- The height of the divider must be greater than or equal to the height of the oven (24.3” or 618 mm).

- Verify oven location has a minimum 16” (406 mm) clearance on top and minimum 2” (51 mm) of clearance on each side.

Optional Installation Items

See Figure 4, page 5.

TurboChef Oven Carts

- Part Number: NGC-1217-1

Height: 24” (610 mm) Width: 27.8” (706 mm) Depth: 26.625” (676 mm)

- Part Number: NGC-1217-2

Height: 17.3” (439 mm) Width: 27.8” (706 mm) Depth: 26.625” (676 mm)

- Part Number: NGC-1217-3

Height: 32” (813 mm) Width: 27.8” (706 mm) Depth: 26.625” (676 mm)

TurboChef Stacking Stand

- Part Number: i5-9369

Height: 44.6” (1133 mm) Width: 32.5” (826 mm) Depth: 26.5” (673 mm)

NOTE: The stacking stand can only be used with the 17.3” (439 mm) oven cart (P/N: NGC-1217-2).

Oven Restraint Kit

Part Number: TC3-0242

WARNING: The Oven Restraint Kit will not prevent the oven from falling off a counter topif the oven is pulled off or allowed to slide off the edge. Installation instructions are included with the kit.

ChefComm Pro (CON-7006)

ChefComm Pro empowers any user of a TurboChef oven to easily and efficiently create menu settings on a computer and transfer them to an oven via smart card or USB device.

ChefComm Limited (CON-7016)

ChefComm Limited is a “read-and-transfer only” version of ChefComm Pro that helps ensure carefully-crafted settings are easy to distribute globally, while providing the peace of mind that they will not be altered.

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SPECIFICATIONS AND INSTALLATION

Figure 4: Oven Carts and Stacking Stand Dimensions

Figure 3: Installation Near Open Heat Source

62.7” (1594 mm) (handle)

35.5” (902 mm) (handle)

35.5” (706 mm)

28.6” (726 mm)

1.5” (38 mm)

30.0” (762 mm)

31.5” (800 mm)

32.5” (826 mm)

44.6” (1133 mm)

17.3”

(439 mm)

15.8”

(401 mm)

20.5” (521 mm)

26.5” (673 mm)

24.3” (617 mm)

Partition

24.3” (618 mm) Above Counter Top

Grill

6” (152 mm) Minimum

TurboChef

i5 Oven

32.0”

(813 mm)

24.0”

(610 mm)

17.3”

(439 mm)

12” (305 mm) Minimum

Counter Top / Table

Partition

24.3” (618 mm) Above Counter Top

Deep Fryer

27.8” (706 mm)

26.625” (676 mm)

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6 SPECIFICATIONS AND INSTALLATION

Voltage Selection

For North America oven models, the oven will detect 208 or 240 incoming voltage.

The initial voltage selection is typically completed before the oven is used by the customer. However, if incoming voltage for the store is different than the preset voltage, the operator will be required to select either 208 or 240 after pressing the On/Off key to turn on the oven. The correct voltage will be enlarged on the screen, identifying which option to select (Figure 5, below).

Ventilation Requirements

The TurboChef model i5 oven has been approved by Underwriter’s Laboratory for ventless operation (UL 710B, KNLZ listing) for all food items except for foods classified as “fatty raw proteins.” Such foods include bone-in, skin-on chicken, raw hamburger meat, raw bacon, raw sausage, steaks, etc. If cooking these types of foods, consult local HVAC codes and authorities to ensure compliance with ventilation requirements.

NOTE: In no event shall the manufacturer assume any liability for damages or injuries resulting from installations which are not in compliance with the instructions and codes previously listed.

Figure 5: Selecting Voltage

208 VAC

SELECT VOLTAGE:

240 VAC

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Daily Maintenance

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DAILY MAINTENANCE

Daily Maintenance

The following steps will help maintain your i5 Oven. Use only TurboChef Oven Cleaner and Oven Guard. The use of any other cleaning products can damage critical oven components, resulting in a non-warranty service call.

Supplies and Equipment

- TurboChef Oven Cleaner (Part Number: 103180)

- TurboChef Oven Guard (Part Number: 103181)

- Nylon scrub pad, cleaning towel, disposable gloves, protective eyewear, dust mask (optional), *pair of tongs wrapped with towel (optional - see step 11)

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 1: Prepare the Oven

WARNING: The oven operates at approximately 500°F (260°C) and may cause injury if not allowed to cool properly.

- Turn off the oven by pressing the On/Off key.

- Slightly open the oven door. Cooling takes approximately 40 minutes.

- DO NOT attempt to clean the oven until the oven displays “Oven Off.”

Step 2: Remove and Clean the Wire Rack

WARNING: Be sure the oven interior is cool before you remove the wire rack.

- Wash, rinse, sanitize, and dry the wire rack.

Step 3: Remove and Clean the Lower Jetplate

- Unscrew the two thumb screws on the lower jetplate.

- Lift the lower jetplate by gripping the thumb screws.

- Remove the lower jetplate.

- Wash, rinse, sanitize, and dry the lower jetplate.

Step 4: Remove and Clean the Lower Air Diverter

- Remove the lower air diverter.

- Wash, rinse, sanitize, and dry the lower air diverter.

WARNING: DO NOT discard the lower air diverter. The oven will not work without the lower air diverter installed.

Step 5: Wipe the Oven Interior

- Wipe any large particles from the oven interior with a damp towel.

Step 6: Clean the Oven Interior

- Spray oven cleaner onto the top, bottom, and sides of the oven interior.

CAUTION: DO NOT spray oven cleaner into the holes on the back oven wall. Doing so can damage critical oven components, resulting in a non-warranty service call.

- Allow Oven Cleaner to penetrate stains for five minutes.

- Clean the oven interior with a nylon scrub pad.

CAUTION: DO NOT apply excessive pressure when wiping the top ceramic jetplate; breakage will result in a non-warranty service call.

CAUTION: DO NOT remove the top ceramic jetplate; breakage will result in a non-warranty service call.

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8 DAILY MAINTENANCE

Step 7

Step 8

Step 9

Step 10

Step 11

Step 12

Step 13

Step 7: Clean and Dry the Oven Door

CAUTION: DO NOT spray cleaner directly onto the oven door gasket (A) or saturate it with water.

CAUTION: DO NOT scrub, scrape, or attempt to clean the oven door gasket (A). Doing so may cause the door to not close properly, resulting in a non-warranty service call.

- Clean the oven door with oven cleaner and a nylon scrub pad.

- Wipe the oven door with a damp towel.

Step 8: Rinse the Oven Interior

CAUTION: DO NOT use a hose or water jet for cleaning. Doing so can damage critical oven components, resulting in a non-warranty service call.

- Rinse the oven interior with clean water.

- Thoroughly dry the oven interior with a clean towel.

Step 9: Apply TurboChef Oven Guard

- Spray Oven Guard onto a clean towel.

- Wipe the oven’s interior walls and the inside of the oven door.

CAUTION: DO NOT apply Oven Guard to the oven door gasket. Doing so may damage the gasket, resulting in a non-warranty service call.

Step 10: Reinstall Components

- Reinstall the lower air diverter.

- Reinstall the lower jetplate. Screw in the two thumb screws to lock the lower jetplate in place.

- Reinstall the wire rack and close the oven door.

Step 11: Clean the Drain Pan

- If required, remove the lower front panel.

- Remove the drain pan entirely from the bottom of the oven.

- Wipe down* the inside of the area the drain pan fits within.

- Empty, clean, and reinstall the drain pan and, if required, the lower front panel.

CAUTION: Ensure the drain pan’s outer edge/ lower front panel is flush with the door panel (i.e., not sticking out). Failure to do so will damage the oven door, resulting in a non-warranty service call.

Step 12: Clean the Oven Exterior

- Wipe the oven exterior with a clean, damp towel.

CAUTION: DO NOT spray chemicals into any openings, such as the louvers on the side panels or the rear vent catalyst housing. Doing so can damage critical oven components, resulting in a non-warranty service call.

Step 13: Clean the Air Filter (once per week)

- Remove the air filter from the back panel.

- Gently wash by hand in the sink or rinse with hot water.

CAUTION: DO NOT use a water jet. Doing so will shorten the life of the filter.

- Reinstall the air filter, or replace it if large holes are present or if the mesh is becoming detached from the frame.

CAUTION: DO NOT operate the oven without the air filter in place.

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Oven Controls and Cooking

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OVEN CONTROLS AND COOKING

Oven Controls

1. Info Key

When the oven is off or cooling down, press to access the Info Mode (see page 13).

2. On/Off Key

Press to turn the oven on (begin warmup) or off (cool down), or to exit Info Mode (page 13).

3. Display

The display shows information relevant to the current oven operation and/or user options.

4. Soft Keys

There are ten soft keys - five to the left and right of the display. Press a soft key to select an option adjacent to that key on the display.

NOTE: Soft keys are labeled L1-L5 and R1-R5 in this manual (where applicable) for identification purposes.

5. Up and Down Keys

When the oven is ready to cook (i.e., warmed up and waiting for a cook command), press the Up or Down key to view additional food groups or items.

When the oven is in the Info Mode (see page 13), press to navigate between screens 1 and 2.

When editing a food item, press to navigate between editable fields (Figure 30, page 20).

6. Back/Stop Key

When the oven is cooking, press the Back/Stop key to immediately terminate a cook cycle. When the oven is ready to cook (i.e., warmed up and waiting for a cook command), or in the Info Mode (see page 11), press the Back/Stop key to return to the previous screen.

7. Enter Key

Press the Enter key when saving changes to food item settings (Figure 30, page 20), or whenever instructed by the oven screen.

8. Numeric Keypad

Use the numeric keypad to enter access passwords or modify cook settings (Figure 30, page 20). The numeric keypad also contains a Back/Stop key and an Enter key, which are functionally identical to Items 5 and 6.

BACK

STOP

ENTER

ABC3DEF

GHI5JKL6MNO

BACK

STOP

ENTER

PQRS8TUV9WXYZ

8833

Figure 6: Oven Controls

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10 OVEN CONTROLS AND COOKING

Step 3: Warming Up

During this step, the oven warms to the selected or pre-set temperature.

Step 2: Select Cook Temperature

The oven can store either one or two cook temperatures. To select a temperature, press the adjacent soft key.

Each temperature has 10 food groups assigned to it, and each group consists of 10 food items (100 items per temperature). The operator will only be able to cook items associated with the selected temperature; to cook other items on the menu, a new temperature must be selected.

NOTE: If both temperature settings are the same, this screen will be bypassed and access to all 200 food items will be allowed.

Step 1: Turn the Oven On

When the oven is off (Figure 7), the oven temperature has receded below 150°F (66°C), but the display and keypad remain on.

Press the On/Off key to turn the oven on.

OVEN OFF

READY TO CLEAN

TURBOCHEF i5

TEMP 1: 500F

TEMP 2: 350F

SELECT COOK TEMPERATURE

WARMING UP

OVEN CC = 244F OVEN SP = 500F

Figure 7: Oven Off

Cooking

The oven is preprogrammed with recipe settings at the time of manufacture and is ready to operate out of the box. If these settings are erased, new menu settings must be either loaded via smart card/USB drive (page 15) or programmed manually (pages 19-20). The oven will not cook unless settings are present.

Note that the steps below are not always sequential. Typically, multiple items will be cooked before cooling the oven (Step 10).

Figure 8: Cook Temperature Select

Figure 9: Warming Up

Page 27

OVEN CONTROLS AND COOKING

Step 6: Adjusting the Time

The Adjust Time option is turned off by default. If you want the ability to modify the cook time before each cook cycle, this feature can be turned on from the “Options” screen (see page 14).

1. If the “Adjust Time” screen appears, change the cook time if needed by using the number keys.

2. Press Enter or bottom-right soft key to confirm and begin cooking.

Step 5: Ready to Cook or “Idle”

WARNING: Inside of oven and oven door are hot!

1. Place the food into the oven.

2. Select a food group by pressing its adjacent soft key, or press the Up or Down key for additional food groups, if available.

3. Select an item to cook by pressing its adjacent soft key.

Step 4: Soaking

Once the oven temperature reaches the set point, the oven will continue to warm for eight minutes to ensure the cook cavity surfaces absorb enough heat so as to not affect cooking results. This process is called “soaking.”

Figure 10: Adjust Time

Step 7: Cooking

NOTE: To immediately terminate a cook cycle, press the Back/Stop key.

NOTE: If the oven door is opened during a cook cycle, the cycle will pause until the door is closed and “Resume” is selected.

Figure 11: Cooking

ADJUST TIME

START COOK

01:40

COOKING

01:17

GROUP 1

ITEM 1

Page 28

12 OVEN CONTROLS AND COOKING

Step 8: Remove Food from Oven

WARNING: Dish and inside of oven/oven door are hot!

Open the oven door and check/remove food.

Figure 12: Cooking Done

Step 9: Additional Cooking Options

The “Additional Cooking Options” screen is turned off by default. If you want the ability to cook a product a little beyond the standard cook time, you can enable this feature from the “Options” screen (see page 14).

If the “Additional Cooking Options” screen appears and the food product requires more cooking:

- Select “cook more” if the inside of the food item is undercooked.

- Select “brown more” if the outside of the food item requires more browning or crispness.

- Select “cook and brown more” if both the inside and outside of the food item are not done.

- Select “save adjusted time” to save any change to the cook time made during Step 6. Note that this option is not available if “Adjust Time” is disabled.

- Select “exit” to return to the food group selection screen.

Figure 13: Additional Cooking Options

Step 10: Cooling Down

When finished cooking for the day, press the On/Off key to turn the oven off and begin cooling down.

During this step, the oven blows cool air into the cook cavity to return it to approximately 150°F (66°C), at which point the oven is safe to clean.

Figure 14: Cooling Down

PLEASE REMOVE FOOD FROM OVEN

COOKING DONE

ADDITIONAL COOKING OPTIONS

COOK AND BROWN MORE

BROWN MORE

COOK MORE

SAVE ADJUSTED TIME EXIT

COOLING DOWN

PLEASE OPEN OVEN DOOR

CC = 288F

Page 29

Info Mode Test Mode Edit Mode

Page 30

Page 31

INFO MODE

Overview of the Info Mode

The Info Mode serves four main purposes:

1. To display oven information.

2. To provide access to Test Mode and additional diagnostic tools for service technicians.

3. To turn oven options and features on/off.

4. To update oven settings.

To access the Info Mode, simply press the Info key when the oven is either off or cooling down. To toggle between screens 1 and 2, press the Up or Down key.

From screen 1 of the Info Mode (Figure 15):

- View the oven serial number

- View the oven software version

- View the menu part number and revision

- View the last temperature selected to cook

- View the electrical compartment temperature

- Scroll through counters (total cook time, magnetron time, total oven on time, and cook counter)

- View the operating voltage (North America models only)

- Access the fault log

- Access service phone numbers

From screen 2 of the Info Mode (Figure 16):

- Access Test Mode

- Access the “Options” screen

- Set the language (not available on all models)

- Set the date/time

- Increase/decrease the tone volume (sound)

- Access the “Load Menu” screen

- Turn the F2 Alarm on or off (page 14 for details)

Viewing Cook Counter/Time Logs

From the Info Mode (Figure 15), press the R1 soft key:

- Once to display total cook time.

- Twice to display total magnetron time.

- Three times to display total “oven on” time.

- Four times to display the cook counter.

Viewing the Fault Log

Figures 17-18. For more information on faults, see pages 35-36. To zero the fault counters, select Clear All.

From the Info Mode (Figure 15), press the R3 soft key to view the fault log (Figure 17). To view a detailed log of each fault occurrence (Figure 18), press the soft key adjacent to the fault code.

MENU P/N AND REV

INFO 1

SOFTWARE VERSION

SP: 500F

EC TEMP: 84F

S/N: i5-DXXXXXX

FAULT LOGS

VAC = 240

SERVICE NUMBERS

COUNTS SCROLL

SET LANGUAGE

INFO 2

SET OPTIONS

SET DATE/TIME 05/01/09 11:14:28

TEST MODE LOAD MENU

SOUND = = = = = = 7

F2 ALARM ON

Figure 15: Info Mode Screen 1

Figure 16: Info Mode Screen 2

F6: EC OT

F8: HX RISE LOW

F1: BLOWER

F2: LOW TEMP

F3: MAG C LOW

F4: MONITOR F9: CC OT

F5: MAG OT

FAULT LOG

F7: RTD OPEN

Figure 17: Fault Log

07/14/09 05:22

F1 FAULT DETAIL

07/14/09 13:54

07/14/09 22:07

07/15/09 08:36

07/18/09 14:35

09/26/09 17:42

12/04/09 20:18

SCREEN 1 OF 13

Figure 18: Fault Detail

R3 R4

L3 L4

R3 R4

L3 L4

R3 R4

L3 L4

R3 R4

L3 L4

Page 32

14 INFO MODE

Viewing the Service Numbers

From the Info Mode (Figure 15, page 13), press the R4 soft key to view technical support contact info.

Resetting the Oven

Resetting the oven is one way to potentially clear an error message, should one occur. When the oven is cooling down or off, press and hold the INFO key for 5 seconds.

Options Screen

From screen 2 of the INFO MODE (Figure 16, page 13), press the L2 soft key to access the Options screen (Figure 19). When prompted, enter the password

9 4 2 8 and press the Enter key.

From the Options screen, the following oven options can be turned on or off:

- Adjust Time screen (see cooking step 6, page 11 for more details)

- Cook More screen (see cooking step 9, page 12 for more details)

- Edit Mode (see page 19 for more details)

- Load Menu screen (see page 15 for more details)

- Demo Mode (TurboChef use only)

- DHCP (TurboChef use only)

- Oven Type: Ensure this option is set to “i5.”

Setting the Language

NOTE: Not available on some oven models.

From screen 2 of the

INFO MODE (Figure 16, page 13),

press the L3 soft key to set a different language. Each

time L3 is pressed, a different language is selected in the following order: English (default), Spanish, French, German, Portuguese, Italian, Russian, Greek, Polish.

Setting the Date/Time

Having an accurate date and time is important for logging oven counts, diagnostics, and fault conditions, should any occur. The oven time and date are set at the time of manufacture; however, the operator may at some point be required to make an adjustment.

From screen 2 of the

INFO MODE (Figure 16, page 13),

press the L4 soft key to access the “Set Date/Time” screen (Figure 20).

To set the date and time,

1. Use the L3 and R3 soft keys (middle left and middle right) to navigate between fields.

2. Use the numeric keypad to enter the month, day, and year, followed by the hour and minute.

NOTE: The clock is a 24-hour clock (e.g., 20:30 = 8:30 PM).

3. Select “Save” to save your changes or “Cancel” to cancel and exit the screen.

NOTE: The oven will not retain the time if it is left unplugged for two or more weeks.

Adjusting the Volume

From screen 2 of the INFO MODE (Figure 16, page 13), press the L5 soft key to adjust the beeper volume.

EDIT MODE

OVEN OPTIONS

COOK MORE

LOAD MENU

DEMO MODE

ADJ TIME DHCPOFF

OFF

OVEN TYPE I5

Figure 19: Options Screen

R3 R4

L3 L4

SET DATE/TIME

0 9 / 2 9 / 0 9 2 0 : 3 0

MM / DD / YY HH:MM

CANCEL

SAVE

Figure 20: Set Date/Time

R3 R4

L3 L4

Page 33

INFO MODE

Setting the F2 Alarm

Under normal operation, the F2 alarm will terminate a cook cycle if the CC temperature falls below 84°F (47°C) of the set point. Turning off the F2 alarm will prevent a cook cycle from being terminated if the fault is discovered. In either event, the fault will be logged for service purposes and should necessitate a service call.

To turn the F2 alarm on or off, press the R2 soft key from the Info 2 screen (Figure 16, page 13).

Making a Copy of the Oven Menu

From screen 2 of the

INFO MODE (Figure 16, page 13),

press the R1 soft key to access the Load Menu screen.

NOTE: This feature can be turned on or off via the “Options” screen (Figure 19, page 14).

To save a copy of the oven menu to a smart card,

1. Insert the smart card (Figure 21).

2. Press the L2 soft key “Save to Card.”

3. Verify the oven beeps and reads “FINISHED.”

To save a copy of the oven menu to a USB drive,

1. Insert the USB drive (Figure 21).

2. Press the L5 soft key “Save to USB.”

3. Verify the oven beeps and reads “FINISHED.”

Updating the Oven Menu

From screen 2 of the INFO MODE (Figure 16, page 13), press the R1 soft key to access the Load Menu screen.

NOTE: This feature can be turned on or off via the “Options” screen (Figure 19, page 14).

To load a menu to the oven via smart card,

1. Insert the smart card (Figure 21).

2. Press the L1 soft key “Load from Card.”

3. Verify the oven beeps and reads “FINISHED.”

To load a menu via USB drive,

1. Verify the menu on the USB drive is named MENU.BIN.

2. Verify the menu on the USB drive is in a folder named TC_MENUS. This folder must not be a sub-folder of any other folder.

3. Insert the USB drive (Figure 21).

4. Press the L4 soft key “Load from USB.”

5. Verify the oven beeps and reads “FINISHED.”

Updating the Oven Firmware

Updating the oven firmware whenever TurboChef releases a new version will help ensure the oven maintains the best possible functionality. Updates can be obtained from www.turbochef.com (link at bottom of screen), and loaded to smart cards via ChefComm. Physical copies can also be ordered and shipped. Contact TurboChef for more details.

CAUTION: Depending on the type of display installed (VFD or TFT) the oven will use a different firmware version. The oven will be inoperable if the incorrect firmware is installed

- Ovens with a VFD display must use i5-3205.

- Ovens with a TFT display must use i5-3206.

From the Oven Off screen,

1. Insert the smart card (see Figure 21).

2. While the oven is either cooling down or off, press and hold the Info key until the oven resets (approximately 5 seconds).

3. When the oven beeps one long high tone, the load was successful. Remove the card and if a second card was provided, insert it.

4. When the oven beeps one long high tone, remove the second card to begin the reboot process.

5. When the oven restarts and the display turns on, the update is complete. Remove the smart card.

6. Verify the oven type is set to “i5” (Figure 19).

NOTE: If the update is unsuccessful, the display will remain off and the oven will beep one long, low tone. If this occurs, repeat the above procedure. If the update fails multiple times, contact TurboChef.

CAUTION: The oven will be inoperable if the firmware update is unsuccessful!

Figure 21: Inserting Smart Card/USB Device

Smart Card

USB Port Smart Card Reader Slot

Page 34

16 TEST MODE

Test Mode - Testing Oven Parts

From screen 2 of the INFO MODE (Figure 16, page 13), press the L1 soft key to access

TEST MODE (Figure 22).

When prompted, enter the password 9 4 2 8 and press the Enter key. From

TEST MODE, the oven’s

components can be tested independently, or a comprehensive/selective self-test can be run. Unless otherwise specified, idle airflow is set to 10% and the stirrer motor is turned on.

Top and Bottom Blower

Each blower can be tested independently of the other, at any speed setting. While one blower is being tested, the other will remain at 10% idle airflow.

Press the L2 soft key (Figure 22) to increase top blower speed in 10% increments.

Press the L3 soft key (Figure 22) to increase bottom blower speed in 10% increments.

Heaters

Press and hold the L4 soft key (Figure 22) to turn on the heaters. They will turn off upon releasing the L4 soft key.

Magnetron Test

Press and hold the L5 soft key (Figure 22) to turn on the magnetrons. To turn off the magnetrons, simply let go of the L5 soft key.

Stirrer

Press the R1 soft key (Figure 22) to turn the stirrer on/off.

Status Indicators

Figure 22. The status indicators are located at the bottom of the

TEST MODE screen, and consist of:

- P = Primary switch (backlit = open)

- S = Secondary switch (backlit = open)

- M = Monitor switch (backlit = open)

- t = Magnetron thermostat (backlit = open)

- H = Heaters (backlit = off)

- B = Bottom blower (backlit = off)

- T = Top blower (backlit = off)

- W = Microwave (backlit = off)

In Figure 22:

- All three door switches are engaged (closed).

- Magnetron thermostat is closed.

- The heaters are on.

- Both blower motors are on.

- Microwave is not being used.

Fault Log

Press the L1 soft key (Figure 22) to access the fault log.

This fault log is identical to the one accessible from

INFO MODE

screen 1 (Figure 17, page 13).

Turning Diagnostic Mode On/Off

Press the R2 soft key (Figure 22) to place the oven in

DIAGNOSTIC MODE. When in DIAGNOSTIC MODE, the

oven displays additional cooking parameters during a cook cycle, including:

- Event currently being cooked

- Time left per event

- % wave, % top air, % bottom air

- Status indicators

- Group and recipe name

- Actual cook cavity temperature

- Set point temperature

For normal oven operation, ensure

DIAGNOSTIC MODE

is turned off.

BOTTOM BLOWER 20%

TEST MODE

TOP BLOWER 10%

HEATERS ON

MAG OFF

FAULT LOG

MANUFACTURING

DIAGNOSTICS OFF

VOLTAGE 240 VAC

STIRRER ON

P S M t H B T W

CC = 408F

Figure 22: Test Mode

R3 R4

L3 L4

Page 35

TEST MODE

Manufacturing Mode

Press the R3 soft key (Figure 22, page 16) to place the oven in

MANUFACTURING MODE (Figure 23). When in

MANUFACTURING MODE, the following tests and

settings can be accessed:

- Microwave leakage test

- Microwave power test

- Burn in

- Serial number edit

- Temperature measurement (F or C)

- Self test

- Erase/default oven settings

Microwave Leakage Test

Press the L1 soft key (Figure 23) to initiate the microwave leakage test. The oven will warm up to 500°F (260°C). When warmup is complete, insert the water load. Follow the steps on pages 25-26.

Microwave Power Test

This test should only be performed by the manufacturer.

Burn-In

Press the L3 soft key (Figure 23) to initiate a 25minute burn-in. This feature helps ensure all cavity walls reach thermal equilibrium before testing is conducted.

Serial Number Edit

Press the L4 soft key (Figure 23) to access the “Edit Serial Number” screen (Figure 24). To edit the serial number:

- Use the number/letter keys to change a character. After one second, the cursor will advance to the next character.

- Press the R3 soft key to advance to next character.

- Press the L3 soft key to return to previous character.

- Press the R5 soft key to save the changes or the L5 soft key to cancel.

Changing Temperature Measurement Setting

Press the L5 soft key (Figure 23) to change the temperature to either Fahrenheit or Celsius.

Self Test

Press the R1 soft key (Figure 23) to access Self Test. From the “Self Test” screen (Figure 25):

- L1 soft key initiates a comprehensive self test. The oven will check the door switches, blowers, magnetrons, and heaters in sequence.

- L2 soft key initiates a door switch test only.

- L3 soft key initiates a blower test only.

- L4 soft key initiates a magnetron test only.

- L5 soft key initiates a heater test only.

When each test completes, the oven will display PASS or FAIL.

SERIAL NUMBER EDIT

i 5 - D 1 0 0 0 1

CANCEL

SAVE

Figure 24: Serial Number Edit

R3 R4

L3 L4

BURN IN

MANUFACTURING MODE

MW POWER TEST

MW LEAK TEST

SERIAL NUMBER EDIT

FAHRENHEIT 382F

SELF TEST

ERASE/DEFAULT

VOLT ON

P S M t H B T W

Figure 23: Manufacturing Mode

R3 R4

L3 L4

MAG TEST

HEATER TEST

AUTO TEST

DOOR TEST

BLOWER TEST

SELF TEST

P S M t H B T W

Figure 25: Self Test

R3 R4

L3 L4

P S M t H B T W

Page 36

18 TEST MODE

Volt On

This setting should not be changed in the field unless instructed by TurboChef. Press the R2 soft key (Figure 23, page 17) to enable/disable the voltage from displaying in

INFO MODE

. Typically, this setting is

disabled for ovens installed outside the United States.

Erase/Default Oven Settings

CAUTION: Settings cannot be retrieved once an erase option is confirmed.

Press the R3 soft key (Figure 23, page 17) to access the Erase screen. From the Erase screen (Figure 26),

- Press the L2 soft key to erase counters and fault logs.

- Press the R2 soft key to erase counters, fault logs, menu settings, temperature settings, serial number, date, and time. Doing so will also default all oven options (page 14 for more detail) to OFF, with the exception of “load menu.”

ERASE SETTINGS

ERASE COUNTERS AND FAULT LOGS

COMPLETE ERASE

Figure 26: Erase Settings

R3 R4

L3 L4

Page 37

EDIT MODE

Overview of the Edit Mode

The EDIT MODE serves three main purposes:

1. To edit set temperatures.

2. To edit names of food groups and recipes.

3. To edit recipe settings.

To access the

EDIT MODE,

1. When the oven is off or cooling down, press the Info key.

2. Press the Down key to access screen 2 and select “Set Options.”

3. Enter the password 9 4 2 8 and press ENTER.

4. From the Set Options screen, press the R3 soft key to turn Edit Mode on.

5. Press the On/Off key to exit the Options screen.

6. Press the On/Off key again to enter

EDIT MODE.

Changing Set Temperatures

The i5 oven can store two set temperatures. Think of each temperature as a “block” of 10 food groups with 10 items each, or 100 items per temperature.

If a menu was loaded via smart card or USB (page

15), the temperatures are already set - they need not be changed. The set temperature should never be

changed during normal operation.

Changing the set temperatures is not advised to compensate for over-cooking or under-cooking. Rather, consult your authorized distributor or TurboChef Customer Service if recipe settings are not cooking as desired.

To change a set temperature,

1. Place the oven in

EDIT MODE (see adjacent).

2. Select the temperature to change by pressing the adjacent soft key (Figure 27).

3. Using the number keys, enter the new set temperature (valid temperature range is 350525°F (175-275°C)).

4. Press the Enter key to confirm the change, or the Back/Stop key to cancel.

EDIT TEMP 1 GROUPSEDIT TEMP 1: 500F

EDIT TEMP 2: 350F EDIT TEMP 2 GROUPS

VALID RANGE BETWEEN 350 - 525F

Figure 27: Temperature Edit Screen

R3 R4

L3 L4

Page 38

20 EDIT MODE

Changing Food Group/Item Name

To change a food group or item name,

1. Place the oven in

EDIT MODE (see page 19).

2. Select a “block” of food groups by pressing the corresponding right-side soft key (Figure 27, page 19).

3. Select the group that contains the item(s) you want to edit (Figure 28).

4. Select an item to edit (Figure 29).

5. From the “Recipe Edit” screen (Figure 30), edit the food group name:

- Use the numeric keypad to change a character.

- Press R1 soft key to advance to the next character.

- Press L1 soft key to return to the previous character.

- Press the R3 soft key to save changes.

6. Edit the item name:

- Press the Down key to move to the “Item Name” field.

- Use the instructions provided in step 5 to edit the item name.

Changing Recipe Settings

To access the Recipe Edit screen, follow the steps in the adjacent section titled Changing Food Group/Item Name.

To change recipe settings,

1. From the Recipe Edit screen (Figure 30), press the Down key to move the cursor to the desired “Event Setting” field.

NOTE: To help make navigation easier, the currentlyselected field will be displayed in the top-right corner of the display. In Figure 30, the cursor is in the “% Time” column.

2. Use the number keys to adjust event settings:

- % Time (0-100% in 1% increments). The sum of the percentages across eight events must equal 100.

- % Top Blower (10-100% in 10% incr.)

- % Bottom Blower (10-100% in 10% incr.)

- % Microwave (0-100% in 10% incr.)

3. Press the R4 “Time” soft key (or press the Down key) to move the cursor to the total time field.

4. Use the number keys to adjust the cook time.

5. Press the R3 soft key to save changes.

NOTE: For the save to take effect, the cursor must be advanced past the field that was last edited.

6. If desired, press the R5 soft key to test the new settings. The oven may require time to warm up.

7. When all editing is complete, return to the Options screen and turn off the

EDIT MODE

(see page 14) to allow access to regular cook mode.

FZN Wings 15 pc

FZN Wings 25 pc

FZN Bnls Wings

Breast 4 pc

EDIT

Chicken and Fowl

FZN Raw Tender X6

Duck Breast 2 pc

Figure 29: Select Recipe to Edit

EVENT %TIM %TOP %BOT %WAV

1 020

100 010 070 2 020% 100 010 080 3 020 100 010 070 4 020

100 010 060 5 020 100 010 040 6 000

010 010 000 7 000 010 010 000 8 000

010 010 000

TOTAL TIME = 01:40

Chicken and Fowl FZN Wings 15 pcs

% TOTAL = 100

SP = 450F CC = 455F

COOK

TIME

%TIM

SAVE

Figure 30: Recipe Edit Screen

Chicken and Fowl

Veggies & Starch

Meat

Seafood

Sandwich

Appetizers

Bake & Casserole

Pizza

Blank Group

Manual Cooking

SP: 500F

Figure 28: Select Food Group

R3 R4

L3 L4

R3 R4

L3 L4

R3 R4

L3 L4

Page 39

Oven Systems

Page 40

Page 41

OVEN SYSTEMS

Convection System

The convection system is designed to rapidly heat, clean, and recirculate air into the cook cavity.

This section contains information about the following components:

- Blower motor (bottom)

- Blower motor (top)

- Blower motor controller

- Heater element

- Jetplate (bottom)

- Jetplate (top)

- Stirrer motor and assembly

For information on accessing and removing parts, see the Appendix.

Blower Motor (Bottom)

The bottom convection motor is a brushless AC switch reluctance type. Its top speed is 7100 RPM at 1 HP. The motor is controlled by a proprietary controller and spins clockwise.

The bottom blower motor can be tested in

TEST

MODE

(see page 16).

Blower Motor (Top)

The top convection motor is a brushless AC switch reluctance type. Its top speed is 7100 RPM at 1 HP. The motor is controlled by a proprietary controller and spins counterclockwise.

The top blower motor can be tested in

TEST MODE

(see page 16).

Blower Motor Controller (BMSC)

The motor controller is proprietary and will only operate the convection motors described above. It is controlled via 0-10 VDC speed command from the control board. The blower motor controller can be tested in

TEST MODE by testing the blower

motors (see page 16). For additional F1 fault troubleshooting, see page 37.

Heater Element

There are two main convection heaters, each rated at 3000 watts at 208 VAC with a resistance of 14.4 ohms. The convection heater is controlled by the K4/K5 solid state relay.

The heater element can be tested in

TEST MODE

(see page 16).

Older oven models use a finned heater while recently manufactured models use a helical heater. If a finned heater fails, the entire heater assembly must be replaced with the newer helical heater assembly (i5-3214) since the helical heaters require a different mounting plate.

Jetplate (Bottom)

The bottom jetplate channels air that is generated from the bottom blower motor into the cook cavity.

Jetplate (Top)

The top jetplate channels air that is generated from the top blower motor. This air passes through a stirrer before entering the cook cavity through the jetplate holes.

CAUTION: The top jetplate is ceramic. Be careful when removing or reinstalling it.

Stirrer Motor and Assembly

The stirrer is responsible for evenly distributing hot air and microwave that are launched from the top of the oven into the cook cavity. The stirrer is driven by a motor that remains on during a cook cycle or when the oven is in

TEST MODE. The

stirrer motor turns off when the cook cavity temperature recedes below 150°F (66°C).

The stirrer motor can be tested in

TEST MODE (see

page 16).

CAUTION: Be careful to not allow debris into the waveguides when servicing the stirrer assembly.

Page 42

Convection System Troubleshooting

The following faults may occur in relation to the convection system:

- F1: Blower (see page 37)

- F2: Low Temp (see page 38)

- F6: EC Temp (see page 41)

- F7: Thermo (see page 41)

- F8: Heat Low (see page 42)

- F9: CC Temp (see page 42)

The following cooking performance issues may occur in relation to the convection system:

- Food not cooking properly (see page 45)

Oven Door

This section contains information about the following components:

- Oven door

- Interlock switches

- Hinges and counter-balance assembly

This section also contains procedures for:

- Removing/reinstalling the oven door

- Adjusting the oven door

- Adjusting the oven door switches

- Adjusting the counter-balance assembly

- Measuring RF leakage for microwave safety

For information on accessing and removing parts, see the Appendix.

NOTE: The proper fit and adjustment of the oven door is essential for safe and reliable oven operation.

The oven door assembly consists of a shunt plate, skin, and handle. Each of these items can be purchased independently.

Removing/Reinstalling the Oven Door

To remove or reinstall the oven door, follow the steps below. For illustrations, see page A-4.

1. Ensure the oven has cooled to 150°F (66°C).

2. Open the oven door to its full open position.

3. Locate and remove the #8-32 screws (3 per side).

4. Carefully remove the oven door by pulling the door away from the oven. It will slide off the hinges and the hinge blocks will stay in place. See Figure A-1, page A-4.

5. To reinstall or fit a new door, carefully slide it back over the hinge blocks and replace the 6 #8-32 screws (3 each side).

6. Verify that the door is parallel to the oven frame. If it is not parallel, adjust the door per the instructions below.

7. From

TEST MODE (page 16), check the status

indicators P, S, and M to verify the switches engage (door closed) and disengage (door open) properly. If they do not, adjust the switches per the instructions on page 24.

8. Complete a MW leakage test (pages 25-26).

Adjusting the Oven Door

Ensuring the oven door is parallel to the cavity frame is essential for safe and proper oven operation. If the door is misaligned, follow the proceeding steps.

CAUTION: This procedure should be performed while oven is hot. To avoid burns, be careful when adjusting the oven door.

1. Turn the oven on and warm it to its operating temperature. If two temperatures are present, warm the oven to the higher of the two temperatures.

2. Remove the oven side panels.

3. Remove the switch assemblies from each side.

4. Loosen the four screws that hold the hinge assembly to the gusset plates (Figure 31A).

22 OVEN SYSTEMS

Page 43

OVEN SYSTEMS

Figure 31A: Properly Adjusted Door - Side Views

Oven Door

Oven Frame

Hinge

SM Switches

Remove Bolts

Oven Door

Hinge

P Switch

Oven Frame

Remove Bolts

Figure 31B: Door Misaligned 1 - Side Views

Tap this corner

Figure 31C: Door Misaligned 2 - Side Views

Tap this corner

Remove

switches,

then tap here

5. Slide the door in and out of the cavity, making sure the gaps between the door and cavity face are the same distance on each side. Figures 31B and 31C show misaligned doors.

6. Tighten the four screws and open/close the door multiple times to confirm adjustment.

7. Reinstall the door switches.

8. With the door closed, set the left side switch (primary) so the paddle is closed but not pushing or binding on itself.

9. Set the right side switches (secondary and monitor) so they are completely closed but not pushing or binding on themselves.

10. Turn the oven on and enter

TEST MODE (page

16 for more details).

11. Observe the status indicators when opening and closing the door and confirm the sequence (PSM open, MSP closed). If necessary, adjust the switches (page 24) and reconfirm the sequence.

12. Reinstall the side panels.

13. Perform a MW Leak Test (pages 25-26).

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24 OVEN SYSTEMS

Interlock Switches

The primary, secondary, and monitor interlock switches engage and disengage in sequence to ensure a proper seal. When the door is opened, the switch sequence is P, S, M. Subsequently, the sequence is M, S, P when the door is closed.

Adjusting the Door Switches

Proper door switch sequence is critical. The safety interlock system is designed to disable the microwave circuit (blow F3 fuse) if the monitor door switch opens before the primary or secondary switches during microwave operation. Verifying the door switchs equence is highly recommended when servicing an oven with a blown F3 fuse.

WARNING: This procedure requires work while the oven is hot. To avoid burns, be careful when adjusting the door switches.

1. Ensure the oven door is closed.

2. Verify the oven door is adjusted properly and the oven is at operating temperature before attempting to adjust the door switches. If the oven has multiple set temperatures, use the highest temperature. If a door adjustment is required, refer to pages 22 and 23 for details.

3. If an open door switch is not allowing the oven to preheat, remove the side panels and loosen and move both the left and right door switch brackets to close the switches.

NOTE: Step 3 is not a completed repair. Proper switch operation must be confirmed before putting the oven into service; continue to step 4.

4. With the oven at operating temperature, enter

TEST MODE (page 16) to view the status

indicators of the primary, secondary, and monitor door switches.

5. Adjust the position of the door switches/ brackets to ensure the proper sequence.

NOTE: Opening the door must show the sequence as P, S, M. Closing the door must show the opposite sequence M, S, P. After final adjustments, retighten the hex bolts and confirm the brackets are secure.

6. Reinstall the side panels.

7. Perform a MW leakage test (page 25)

Hinges and Counter-Balance Assembly

The door hinges and counter-balance assembly ensure the door consistently opens and closes smoothly. The counter-balance assembly also allows the door to remain open at convenient positions; i.e., partially open, fully open.

Adjusting the Counter-Balance Assembly

Adjustments either increase or decrease the amount of counter-pressure being applied to the door.

WARNING: This procedure requires work while the oven is hot. To avoid burns, be careful when adjusting the counter-balance assembly.

NOTE: In Figure 32, some oven components have been removed for clarity. The adjustment procedure must be performed with the counter-balance and hinges installed to the oven chassis.

1. Heat the oven to operating temperature.

2. Ensure the door is adjusted properly and closed. Refer to page 22 “Adjusting the Oven Door.”

3. Remove both side panels.

4. Remove both left and right side door switch assemblies for access to the adjustment area.

5. Remove the last gusset screws (closest to the switch assemblies) for tool access.

6. Use adjustment tool P/N i5-9387 to check the distance between the bracket and counterbalance assembly (see Figure 32).

7. Insert the adjustment tool and use a 3/32” hex wrench to tighten the adjustment screw against the bracket so the tool cannot slide out.

8. Loosen the screw just enough to allow the tool to be removed.

9. Repeat steps 5-8 for the other side.

10. Reinstall the gusset screws and tighten.

11. Reinstall the door switch assemblies, verifying the switches are in the closed position (i.e., snug against the actuator).

12. Warm up the oven, allowing the additional 8 minute “soak” to achieve thermal equilibrium in the cook cavity.

13. Adjust the door switches to ensure the proper opening and closing sequence (details adjacent).

14. Reinstall all components and side panels.

15. Test for microwave leakage before returning the oven into service (page 25).

Page 45

OVEN SYSTEMS

Measuring RF Leakage for Microwave Safety

WARNING: Procedure requires work while the oven and water loads are hot. As a result, exercise extreme caution when testing.

An RF (microwave) leakage test must be performed at the conclusion of the following service tasks:

- Door removal, replacement and/or adjustment

- Wave guide removal and /or replacement

- Magnetron removal and/or replacement

- Door switch adjustment and/or replacement

- Counter-balance assembly adjustment and/or replacement

WARNING: If the unit fails the microwave leakage test (leakage greater than 5mW/cm

), the oven must be taken out of service immediately until the defect is corrected. In addition, the

CDRH Regulation 21 Subpart C, 1002.20 requires that leakage readings of over 5mW/cm

must be reported to the manufacturer.

To measure RF leakage,

1. Place the oven in

WARMING UP MODE (page 10,

steps 1-3) and allow it to warm up to the set temperature (approximately 15 minutes if the oven starts cold).

2. Once the oven has warmed up, place the oven in

TEST MODE (see page 16). From TEST MODE,

select “MFG Mode.”

3. From the Manufacturing Mode screen, select “MW Leak Test” and follow the instructions on the screen (also detailed in following steps).

Continued on page 26.

Figure 32: Counter Balance Adjustment

Step 4

Step 7 = Tighten, Step 8 = Loosen Slightly

Step 6: Top of gauge should be flush against the top of the bracket.

Step 6: Screw fits all the way into the notch.

3-32”

Step 5

Page 46

26 OVEN SYSTEMS

4. Place a water load into the cook cavity. Water load must conform to the following specifications:

- Volume: 275 ml ± 15 ml

- Temperature: 68ºF ± 9ºF (20ºC ± 5ºC)

- Vessel: Low form, 600 ml beaker with an inside diameter of approximately 3.35" (85 mm) and made of Pyrex or equivalent.

5. Close the oven door and press the Enter key. The microwave system will turn on.

6. Position the microwave survey meter where the door seals to the oven frame, moving it while testing as shown in Figure 33.

7. Measure microwave emission around the door, moving the meter sensor at 0.5 inches (1.3 cm)/second. As microwave leakage is observed while moving the sensor, note any meter spike areas that come close to 5mW/cm

for later re-

measurement.

8. Replace the water load every 60 seconds until the test is completed, and also after scanning the door.

9. Close the oven door and return the meter probe to any meter spike areas and allow the probe to remain in the spike area for 17 seconds. Note the highest reading obtained.

NOTE: There may be several places on the door that require this procedure. If so, start out with a freshwater load each time a new area is measured, or if measurement of an area takes longer than 60 seconds.

10. After each test is complete, open the oven door and dispose of the hot water.

Oven Door Troubleshooting

The following faults may occur in relation to the oven door:

- F4: Monitor (see page 40)

The following issues may occur in relation to the oven door:

- “Cook Door Open” message when door is closed (see page 43).

Figure 33: Survey Meter Placement

Page 47

OVEN SYSTEMS

Microwave System

Older i5 oven models employ two independent microwave systems (left and right). In the case of an over-current situation relative to the left system, the F3 fuse will blow. In the case of an overcurrent situation relative to the right system, the F4 fuse will blow.

i5 ovens with serial numbers after 00501 are not equipped with an F4 fuse. Both the left and right systems are wired to the F3 fuse. In the case of an over-current situation, the F3 fuse will blow, shutting off both systems immediately.

This section contains information about the following components:

- Capacitors

- Filament transformers

- High-voltage Diodes

- High-voltage Transformers

- Magnetrons

- Stirrer motor and assembly

- Waveguides

This section also contains procedures for:

- Testing a capacitor

- Wiring the filament transformers

- Testing a high-voltage diode

- Wiring the high-voltage transformers

- Testing a filament or high-voltage transformer

- Testing a magnetron for an open/shorted filament

For information on accessing and removing parts, see the Appendix.

Capacitors

- Capacitor rating is 0.91uF, 2500 VDC for all 60 Hz installations (except Japan).

- Capacitor rating is 1.15uF, 2500 VDC for all 50 Hz installations.

- Capacitor rating is 0.85uF, 2500 VDC for 60 Hz Japan installations.

Testing a Capacitor

DANGER: Never attempt any measurement of the capacitors while they are enabled. Lethal voltage will be present. Measure only in compliance with these procedures.

1. Disconnect the oven from the power source.

2. Remove the top cover of the oven.

3. Fully discharge the capacitor.

4. Isolate the capacitor from the circuit.

5. Check for an open or shorted capacitor by placing ohmmeter leads between the capacitor terminals:

- Rising/escalating ohm readings = capacitor OK

- Constant infinite resistance = capacitor open

- Constant very low resistance = capacitor shorted

6. If the capacitor is not open or shorted, set the meter to measure capacitance and again place the leads between the capacitor terminals. The meter reading should equal the label value, plus or minus 10%. If not, replace the capacitor.

Filament Transformers

For better operation and reliability, the oven uses separate transformers in order to preheat the magnetron filament.

The control energizes the filament transformers for approximately five seconds prior to energizing the Microwave Circuit via the high-voltage transformers. When in operation, the filament transformers supply approximately 3.15 VAC at 10 amps to each magnetron filament. The filament transformers are controlled via the K1 relay.

Wiring the Filament Transformers

DANGER: Never attempt to measure the secondary voltage values of the filament transformers when they are enabled. Lethal voltage will be present.

The installation of filament transformers is straightforward. Filament transformers are wired in-phase and in-line. Refer to the schematic on page 49, detailing the proper wiring.

To verify correct wiring (North America), measure the voltages between terminals

1&2and

1&3on FT1 and FT2. The voltages must be 208

and 240 VAC respectively.

Continued on page 28.

Page 48

28 OVEN SYSTEMS

NOTE: The terminals with the orange dot or the orange wire always go to Terminal 3 on US models.

To verify correct wiring (International), measure the voltage between the taps on FT1 and FT2. The voltage must be 220 VAC (Latin America), 200 VAC (Japan), or 230 VAC (International).

High-Voltage Transformers

High-voltage transformers are a ferro-resonant design which limits fault currents and minimizes magnetron power changes due to input voltage changes. The high-voltage transformer supplies the high voltage for the voltage doubler circuit. They are controlled via the K2 relay.

Wiring the High-Voltage Transformers

DANGER: Never attempt to wire or measure the secondary voltage values of the high-voltage transformers while they are enabled. Lethal voltage will be present.

The proper reinstallation of a high-voltage transformer is critical. Upon removing a highvoltage transformer, make sure to note where each wire was installed. Refer to the oven schematic (page 49) detailing the proper wiring.

As shown in the schematic, transformers are installed mirror opposite and wired

180

out-ofphase. It is essential for longevity that the highvoltage transformers remain 180ºout-of-phase. This can be checked by placing a volt meter across terminals

T1-1

and T2-1 (primary voltage).

With the microwave system energized, the volt meter will read

the incoming voltage (different

readings for different electrical installations).

If the

meter reads

0 VAC, the high-voltage transformers

are most likely wired in-phase. As a last check, energize the microwave system and verify the voltages between the taps on each high-voltage transformer. The wiring issue must be corrected prior to returning the oven to service, as the voltages must be:

NORTH AMERICA: 208 VAC between 1&2and

240 between

1&3.

- LATIN AMERICA: 220 VAC

- JAPAN: 200 VAC

- INTERNATIONAL: 230 VAC

NOTE: The terminals with the orange dot/orange wire always go to terminal

3 on USA models.

Testing a Filament or HV Transformer

DANGER: Never attempt to measure the secondary voltage values of the transformers when they are connected to the magnetron circuit. Lethal voltage will be present.

1. Disconnect the AC power source.

2. Remove the top cover of the oven and discharge the high-voltage capacitors.

3. Disconnect all the wires in question going to the transformer.

4. Use an ohmmeter to check the impedance of the primary and secondary winding. Refer to the adjacent resistance table to determine if the transformer is OK. If the resistance is different than the table indicates, replace the transformer.

High-Voltage Diodes

The high-voltage diode (Figure 34) is assembled by connecting several 1000-1500 volt semi-conductor diodes in a series to increase the reverse voltage capability. In the circuit, the high-voltage diode conducts to prevent the filament voltage from becoming positive, thus as the high-voltage winding of the transformer goes to a peak of 2400 volts, the high-voltage capacitor is charged to 2400 volts.

Figure 34: High Voltage Diode

Page 49

OVEN SYSTEMS

When the high-voltage winding starts to go toward negative, the high-voltage diode becomes nonconducting with the charged high-voltage capacitor in series with the high-voltage winding. When the transformer gets to its negative peak of -2400 volts, the voltage applied to the filament is -4500 volts. The high-voltage diodes are rated at 16 kVDC.

Testing a High-Voltage Diode

DANGER: Never attempt to measure high voltage directly. Death or serious injury could result.

1. Disconnect the oven from the power source.

2. Remove the top cover of the oven.

3. Fully discharge the capacitors.

4. Connect the voltage meter in series with diode.

5. 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.

6. 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.

7. 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.

High Voltage Transformers Primary Voltage, Frequency, Taps,

and Resistance

Secondary Taps and Resistance

NGC-3062-1 208 VAC, 60 Hz, 1 & 2,

0.819–1.001

240 VAC, 60 Hz, 1 & 3,

0.972–1.188

4, Ground, 53.60–65.52

NGC-3062-2 230 VAC, 50 Hz, 1 & 2,

0.972–1.188

3, Ground, 57.52–70.30

NGC-3062-3 200 VAC, 50/60 Hz, 1 & 2,

0.784–0.958

3, Ground, 55.75–68.13

Filament Transformers Primary Voltage, Frequency, Taps,

and Resistance

Secondary Taps and Resistance

NGC-3061-1 208 VAC, 60 Hz, 1 & 2,

17.49–21.37

240 VAC, 60 Hz, 1 & 3,

20.61–25.19

4, 5, very low resistance - if reading is open, transformer has failed.

NGC-3061-2 230 VAC, 50 Hz, 1 & 2,

18.99–23.21

3, 4, very low resistance - if reading is open, transformer has failed.

NGC-3061-3 200 VAC, 50/60 Hz, 1 & 2,

15.70–19.18

3, 4, very low resistance - if reading is open, transformer has failed.

High Voltage and Filament Transformer Resistance Table

Page 50

30 OVEN SYSTEMS

Magnetrons

Figure 35. Magnetrons supply the RF energy at

2.45 GHz and begin to oscillate when they are supplied with approximately 4.1 kVDC at approximately .350 mA. During operation each magnetron will output a nominal 1 kW of power.

If replacement is required, conduct a microwave leakage test (pages 25-26) after installation of new magnetron.

Testing a Magnetron for an Open/Shorted Filament

DANGER: The only safe way to test a magnetron is by a resistance test of its filament. Never attempt to measure the magnetron using any other method while the microwave system is on. Death or serious injury could occur.

1. Disconnect the AC power source.

2. Remove the top cover of the oven and discharge the high-voltage capacitors.

3. Isolate the magnetron from the circuit by removing the wires from the F and FA terminals (Figure 35).

4. An ohmmeter connected between the filament terminals (F, FA) should indicate a reading of less than 1 ohm. Figure 35.

5. A continuity check between either filament terminal and the magnetron chassis should indicate an infinite resistance (open).

CAUTION: Be careful to not allow debris into the wave guides when servicing the magnetrons.

Stirrer Motor and Assembly

The stirrer is responsible for evenly distributing hot air and microwaves that are launched from the top of the oven into the cook cavity. The stirrer is driven by a motor that remains on during a cook cycle or when the oven is in TEST MODE

. The stirrer motor turns off when the cook cavity temperature recedes below 150°F (66°C).

The stirrer motor can be tested in

TEST MODE (see

page 16).

CAUTION: Be careful to not allow debris into the waveguides when servicing the stirrer assembly.

Waveguides

The waveguides channel microwaves into the cook cavity. If debris or contamination gets into the waveguides, the life of the magnetrons may be shortened. Be careful to not allow debris into the waveguides when servicing the magnetrons or stirrer assembly.

Microwave System Troubleshooting

The following faults may occur in relation to the microwave system:

- F3: Magnetron Current Low (see page 39)

- F5: Magnetron Over Temperature (see page 40)

The following issues may occur in relation to the microwave system:

- Electrical component failure (blank or scrambled display, damaged control board, etc.)

- Food not cooking properly (see page 45)

Figure 35: Magnetron

FFA

FILAMENT AND HIGH VOLTAGE TERMINALS

ANTENNA

Page 51

OVEN SYSTEMS

Control System

This section contains information about the following components:

- Control board

- Display

- Electrical compartment cooling fans

- Electrical compartment cooling fan thermostat

- Electrical compartment thermocouple

- EMI Filter

- Fuses

- High-limit thermostat

- Keypad

- Magnetron cooling fans

- Magnetron thermostats

- Power Supply

- Relay (K1 - Filament)

- Relay (K2 - Anode)

- Relay (K3 - Monitor)

- Relay (K6 - Voltage)

- Relay (K7 - Mag fan)

- Relay (K8 - Stirrer)

-RTD

- Smart card reader

- Solid state relay (K4/K5 - Heater)

- Speaker

- USB port

- Voltage sensor

- Wire harness

Control Board

The control board controls each electrical component of the oven. See page 49 for a schematic. 24 VDC can be measured at pin 2 of the J7 connector.

Display

The TFT high-resolution display is the primary user interface. Older oven models may be equipped with a VFD display. If the display needs to be replaced (either VFD or TFT), use the TFT display service kit (i5-3207).

Electrical Compartment Cooling Fans

The cooling fans (located in the rear of the oven) are actuated by the cooling fan thermostat when the temperature of the electrical compartment reaches 120ºF (49ºC).

Electrical Compartment Cooling Fan Thermostat

The cooling fan thermostat actuates the rear cooling fans when the electrical compartment temperature reaches 120ºF (49ºC).

Electrical Compartment Thermocouple

The electrical compartment thermocouple measures the temperature of the electrical compartment. If the temperature of the electrical compartment is above 158ºF (70ºC), an F6: EC TEMP fault will display. The control board checks the temperature of the electrical compartment once every 60 seconds.

The electrical compartment thermocouple cannot be replaced on its own if it fails; rather, the control board must be replaced.

EMI Filter

The EMI filter helps suppress the amount of RF interference emitted by the oven.

Fuses

i5 ovens with serial numbers after 00501 are equipped with three fuses. The F1 and F2 fuses are 12-amp, ATMR. The F3 fuse is 20-amp ATMR.

Older i5 oven models may be equipped with four 12-amp ATMR fuses.

The F1 fuse (via blue wire) or F2 fuse (via brown wire) is designed to blow in case of an over-current situation relative to the following components:

- BMSC motor controller

- Electrical compartment cooling fans

- Filament transformers

- Magnetron cooling fan

- Power supply

- Stirrer motor

The F3 fuse is designed to blow in case of an overcurrent situation relative to the microwave system (magnetrons, HV transformers, diodes, capacitors), or a failure with the door interlock switches. See page 24 for door switch adjustment details.

If the oven is equipped with an F4 fuse, the F3 fuse controls the left microwave system while the F4 fuse controls the right microwave system.

Page 52

32 OVEN SYSTEMS

High Limit Thermostat

The high limit thermostat is a 250 VAC, 3-pole, manual-reset thermostat with a trip point of 572ºF (300ºC). The thermostat interrupts power to the main convection heater in the event of an abnormal condition.

Reset the high-limit thermostat by pressing the reset button (Figure 36).

Keypad

The keypad is a 7 x 10 matrix membrane switch. For details on key functions, see page 9.

Magnetron Cooling Fans

The magnetron cooling fans supply air to the magnetrons, and are actuated by the K7 relay. They operate at:

- 208/240 VAC (60 Hz installations with voltage sensing)

- 220 VAC (60 Hz installations with no voltage sensing)

- 230 VAC (50 Hz installations)

- 200 VAC (Japan installations)

Magnetron Thermostats

The magnetron thermostats are “open-on rise.” They are designed to open at 212ºF (100ºC), which triggers an F5 fault.

NOTE: The magnetron thermostats are wired in series. If one opens, the control will switch off both microwave systems until the open thermostat closes. The thermostats are self-resetting.

Power Supply

The power supply outputs 24 VDC at 40 watts to the control board and relays.

Relay - K1 Filament

The K1 relay is a 240 VAC, 30 amp, double-pole, double-throw, 24 VDC relay coil. It switches power to the magnetron filament transformers.

Relay - K2 Anode

The K2 relay is a 240 VAC, 30 amp, double-pole, double-throw, 24 VDC relay coil. It switches power to the magnetron high-voltage transformers.

Relay - K3 Monitor

The K3 relay is a 240 VAC, 30 amp, double-pole, double-throw, 24 VDC relay coil. It shorts L1 and L2 if the monitor switch opens before the primary or secondary switches.

Relay - K6 Voltage

The K6 relay is a 30-amp, three-pole, doublethrow, 24 VDC relay coil. Utilized in North America only, it switches between 208 and 240 VAC on the high-voltage transformer and filament transformer taps (depending on incoming voltage). Through the voltage sensor, the oven defaults to the 240V position and switches to 208 if less than 222 volts is detected. 230V/400V international ovens and all Japan models utilize the N.C. contacts of this relay to power the magnetron circuit.

Relay - K7 Magnetron Cooling Fan

The K7 relay is a 240 VAC, 30 amp, double-pole, double-throw, 24 VDC relay coil. It switches power to the magnetron cooling fans when the magnetron filaments are actuated. The control board switches off power after 4 minutes, 15 seconds.

NOTE: The 4:15 timer starts over each time the magnetron filaments are actuated.

Relay - K8 Stirrer Motor

The K8 relay is a 240 VAC, 30 amp, double-pole, double-throw, 24 VDC relay coil. It switches power to the stirrer motor.

Figure 36: High-Limit Reset Button

Reset Button

Page 53

OVEN SYSTEMS

RTD

The RTD is a resistance temperature detector used to detect the cavity temperature. If the display reads “999°F/C”, the RTD is open, resulting in an F7 fault. See page 41 for troubleshooting.

Testing Procedure

1. Disconnect power from the oven.

2. Open the top cover of the oven, ensuring the supports are in place, and remove the right-side cover.

3. Disconnect the RTD from the control board and remove it from the heater assembly.

4. Place the RTD in ice water for two minutes.

5. Take a resistance reading of the RTD.

6. If RTD resistance is not 100 W, RTD is defective and must be replaced.

NOTE: Use Figure 37 below to determine resistance readings at temperatures other than freezing.

Smart Card Reader

The smart card reader allows the oven operator to load menu or firmware updates from a smart card. An oven’s menu can also be saved to a smart card. For instructions, see page 15.

Solid State Relay - K4/K5 Heater

The solid state relay is a 240 VAC, dual 40-amp relay. K4 (right) switches power to heater 1. K5 (left) switches power to heater 2.

Speaker

The speaker provides audible feedback to the oven operator whenever a key is pressed or a task (such as a cook cycle) is completed.

USB Port

The USB port allows the oven operator to load menu or firmware updates from a USB drive. An oven’s menu can also be saved to a USB drive. For instructions, see page 15.

Voltage Sensor

For North America oven models, the oven will detect 208 or 240 incoming voltage.

Wire Harness

The wire harness distributes power to the oven’s electrical components. See page 49 for a schematic.

Control System Troubleshooting

Potentially, any fault may occur in relation to the control system. See section “Fault Code Troubleshooting,” pages 37-42.

Potentially, any one of the issues diagnosed in the section “Non-Fault Code Troubleshooting” may occur in relation to the control system. See section “Non-Fault Code Troubleshooting,” pages 43-48.

ºF 0º +20º +40º +60º +80º +100º +120º +140º +160º +180º +200º

0º

90.03W 97.39W 101.74W 106.07W 110.38W 114.68W 118.97W 123.24W 127.50W 131.74W 135.97W

+200º

135.97W 140.18W 144.38W 148.57W 152.74W 159.90W 161.04W 165.17W 169.29W 173.39W 177.47W

+400º

177.47W 181.54W 185.60W 189.64W 193.67W 197.69W 201.69W 205.67W 209.64W 213.60W 217.54W

+600º

217.54W 221.47W 225.38W 229.28W 233.17W 237.04W 240.90W 244.74W 248.57W 252.38W 256.18W

ºC 0º +10º +20º +30º +40º +50º +60º +70º +80º +90º +100º

0º

100.00W 103.90W 107.79W 111.67W 115.54W 119.40W 123.24W 127.07W 130.89W 134.70W 138.50W

+100º

138.50W 142.29W 146.06W 149.82W 153.58W 157.31W 161.04W 164.76W 168.46W 172.16W 175.84W

+200º

175.84W 175.91W 183.17W 186.82W 190.45W 194.07W 197.69W 201.29W 204.88W 208.45W 212.02W

+300º

212.02W 215.57W 219.12W 222.65W 226.17W 229.67W 233.17W 236.65W 240.13W 243.59W 247.04W

Figure 37: Temperature/Resistance Relationship Class B. Resistance @ 0ºC = 100.0, Alpha = 0.003850

Page 54

34 OVEN SYSTEMS

Filtering System

This section contains information about the following components:

- Catalytic converter

- Drain pan

- Air Filter

- Vent catalyst

Catalytic Converter

The catalytic converter, a VOC type catalyst, is located behind the rear cook cavity wall and is responsible for cleaning the recirculating airflow. The catalyst functions by substantially lowering the combustion temperature of grease entrained in the air path to approximately the same temperature of the airflow, thus the grease burns and breaks down into CO

and H2O as it passes through the catalytic converter. The catalyst will operate most efficiently at temperatures above 475ºF (246ºC).

The catalytic converter is self-cleaning. Under normal conditions, it does not need to be cleaned and is not considered to be a component that requires scheduled maintenance. Furthermore, the catalyst material is very sensitive to certain chemical compounds. Irreversible damage can occur if the catalyst is exposed to cleaning chemicals containing phosphates, NaOH, silicates, Na and Potassium Salts. These chemicals are found in most commercial degreasers and cleaners; therefore, use only TurboChef

Oven Cleaner when cleaning the oven.

Drain Pan

The drain pan collects debris as it is flushed through the bottom of the cook cavity.

Older i5 oven models utilize a drain pan and lower front panel that allows removal of the drain pan without removing the front cover. This style of drain pan and lower front panel are obsolete. They have been replaced with a new covered lower front panel (i5-9282) and a recessed drain pan (i3-

9252).

The recessed drain pan is functionally the same as the old-style drain pan and can be used with the old-style lower front panel; however, there are visual differences since it is designed to fit with the new covered lower front panel.

The new covered lower front panel is not compatible with the old-style drain pan. If the oldstyle lower front panel is replaced with the new covered lower front panel, the old-style drain pan must be replaced with the recessed drain pan.

Air Filter

The filter is located on the back of the oven. It helps prevent debris from getting into the electrical compartment. This component requires scheduled maintenance and occasional replacement, as it must be kept clean and in good working condition to ensure proper air circulation to the electrical components of the oven. See page 8, step 13 for detailed instructions.

Vent Catalyst

In addition to the main catalytic converter, the i5 oven contains an additional catalyst in the vent tube path. This catalyst further assists in the breakdown of grease and particulate matter before the excess air enters the atmosphere.

Filtering System Troubleshooting

The following issues may occur in relation to the filtering system:

- F9: CC Temp (if the catalyst is clogged with grease and debris - see page 42)

- Fire in the cook cavity (if catalytic converter is clogged due to oven not being cleaned regularly).

- Electrical component failure (if filter is not present or is clogged).

- Undesirable flavor transfer.

- Undesirable odor emissions.

Page 55

Troubleshooting

Page 56

Page 57

TROUBLESHOOTING

Overview of Troubleshooting

This section contains information on the following:

- Fault code descriptions

- Fault code troubleshooting

- Non-fault code troubleshooting

For information on accessing

TEST MODE

, see page

16. For information and illustrations on replacing components, see the appendix.

Fault Code Descriptions

To view the fault log:

1. When the oven is off or cooling down, press the INFO key.

2. Press the R3 soft key to view the fault counters.

3. To view a detailed log of each fault occurrence, press the soft key adjacent to the fault code.

F1: Blower Running Status Bad

This fault is displayed when the motor controller indicates no running status.

The motors and motor controller are monitored continuously in all modes with special handling in the

TEST MODE (see page 16). If a fault is detected,

the control will terminate a cook cycle and display “F1: Blower.”

Upon turning on the oven, the control will attempt to restart the motors. If the restart of both motors is successful, the fault code will be cleared from the display. The fault is also cleared from the display at the onset of cooking or when a blower motor is tested in

TEST MODE.

F2: Cook Temperature Low

This fault is displayed if the cook cavity temperature is more than 84ºF (47ºC) below the set temperature after five seconds into a cook cycle.

The fault is cleared from the display at the onset of cooking if the cook cavity temperature is within 84ºF (47ºC) of the set temperature or when the heater is tested in

TEST MODE (see page 16).

NOTE: The F2 alarm can be turned off to prevent the cook cycle from being interrupted. See page 14 for details.

F3: Magnetron Current Low

This fault is displayed when the current transformer (CT) on the I/O control board detects less than 10 amps. The fault is monitored when the microwave is on during a cook cycle or in

TEST

MODE

The fault is cleared from the display at the onset of a cook cycle if the CT detects 10 amps or when the magnetrons are successfully energized in

TEST

MODE

F4: Door Monitor Defective

This fault is displayed when the control detects that the monitor interlock switch unlatches before the primary or secondary interlock switches. In addition, this fault will blow the F3 fuse (F3 and F4 fuse for ovens equipped with an F4 fuse) if the microwave high voltage system is energized when the fault occurs. The fault is cleared from the display when the oven is powered off and then back on.

NOTE: See the oven schematic, page 49. The fault is monitored during a cook cycle and in

TEST

MODE

when the microwave is on.

F5: Magnetron Over Temperature

This fault is displayed when either magnetron thermostat reaches 212ºF (100ºC).

The thermostats will reset automatically, and are wired in series. The fault is cleared from the display at the onset of a cook cycle if the thermostat is closed or when the magnetrons are successfully tested in

TEST MODE.

F6: Electrical Compartment Temperature High

This fault is displayed when the EC thermocouple exceeds 158ºF (70ºC). The EC temperature is monitored once per minute.

The fault is cleared from the display if on the next check, the EC thermocouple temperature is below the indicated limit.

Page 58

36 TROUBLESHOOTING

Fault codes are listed in order of hierarchy. For example, if during cooking the oven experiences an F1 and F2 fault, the oven will report only the F1 fault because the software will halt all actions upon discovering the F1 fault.

Fault codes F1 - F5 and F7 will terminate a cook cycle upon discovery.

F7: RTD Open

This fault is displayed when the control detects that the RTD is “open” for more than two continuous minutes. The display will show a reading of “999ºF/C,” indicating the RTD is open.

The fault is cleared when the control detects ohms in a proper range. See Figure 37, page 33 for an ohm/temperature chart.

F8: Heat Low

This fault displays during

WARMING UP or TEST

MODE

if the cook cavity temperature fails to rise at

least 14ºF (7ºC) within a given 30 seconds.

F9: Cook Cavity Temperature High

This fault will signal that the catalyst has “flashed” due to excessive grease. The fault occurs when the RTD senses +650°F (343°C) for more than 40 seconds but less than 2 minutes. The fault will only appear in the fault log and will not terminate a cook cycle upon discovery.

Figure 38: Fault Code Table

Fault Code and Description When Active Refer to...

Warmup Idle Cooking Test Mode

F1: Blower Running Status Bad

   

Page 37

F2: Cook Temperature Low



Page 38

F3: Magnetron Current Low

 

Page 39

F4: Door Monitor Defective

 

Page 40

F5: Magnetron Over Temperature

 

Page 40

F6: EC Temperature High

   

Page 41

F7: RTD Open

   

Page 41

F8: Heat Low



Page 42

F9: Cook Cavity Temperature High

 

Page 42

Page 59

TROUBLESHOOTING

To From Description Expected Resistance

Black Red Winding (A-B) 5.9-7.3 Ohms

Black White Winding (A-C) 5.9-7.3 Ohms

Red White Winding (B-C) 5.9-7.3 Ohms

Black, Red, or White Green Windings to Chassis Open

Figure 39: Motor Windings Resistance Table

Fault Code Troubleshooting

From TEST MODE, you can run oven diagnostics and check fault counts. To access TEST MODE or turn on Diagnostic mode, see page 16. For illustrations on removing/replacing oven components, see the appendix at the end of this manual.

Troubleshooting:

F1: BLOWER (Blower Running Status Bad)

YES

Replace blower motor(s).

Check the wire harness and if necessary, replace the control board.

Remove obstruction or if necessary, replace blower motor(s).

YES

Do resistance measurements between windings and chassis agree with values on motor windings resistance table (below)? (Be sure to check both the top and bottom blower motors.)

Is each blower motor spinning freely?

Are Status Indicators “B” and “T” backlit in

TEST MODE

? (page 16)

YES

Replace motor controller.

1. Locate remote test points on the wiring harness (left side).

2. Ground QC11-3 (top) and QC11-6 (bottom) to chassis to remove the backlight from the status indicators.

3. While grounded, check the terminals on the control wiring plug for 0-10 VDC (see schematic (page 49) for QC11 reference) while incrementing the blower speed in

TEST MODE.

Is DC voltage present throughout all speed settings in

TEST MODE?

Page 60

38 TROUBLESHOOTING

Troubleshooting:

F2: LOW TMP (Cook Temperature Low)

YES

Replace the defective heater.

Replace the solid state relay.

YES

Correct wiring.

YES

Reset and determine why it tripped – excess grease buildup, etc. (Figure 36, page 32)

Is either of the heater elements defective? (heaters should have a resistance of

14.4 Ohms)

Is the high-limit thermostat tripped?

Is the solid state relay defective?

Is wiring from the solid state relay to the I/O control board OK? (See page 49 for schematic)

YES

Replace the I/O control board.

YES

Ensure wiring is correct. If necessary, replace RTD.

Is the customer overloading the cavity with frozen product?

Enable the “F2 Alarm Off” mode (see page 14). This will allow the oven to continue to operate if the temperature drops during an overload condition.

Is the RTD functioning properly?

Page 61

TROUBLESHOOTING

Replace the filament transformer(s).

Troubleshooting:

F3: MAG CURR (Magnetron Current Low)

Replace K6 relay.

U.S.

Intl.

Is the K6 mechanical relay in good working order?

Is the oven International or U.S.?

YES

Confirm the F3 fuse is a 20-amp ATMR fuse. Is it open/blown?

Energize the magnetron circuit from Test Mode (page 16). Are there 10+ amps present on the current transformer wire, located on the control board?

Replace the F3 fuse and verify the operation of the interlock switches (page 24).

YES

Reinstall all components and place the oven back in service.

YES

Replace the control board.

YES

Replace affected components.

Test the high-voltage transformers (page 28). Are the transformers functioning properly?

Test the filament transformers (page 28). Are the filament functioning properly?

Replace the capacitor(s).

Test the capacitors (page 27). Are the capacitors functioning properly?

Replace the high-voltage diode(s).

Replace the high-voltage transformer(s).

Is primary voltage present at the high-voltage transformers (page 28)?

NEVER TEST SECONDARY

VOLTAGES

Replace the control board.

YES

Inspect/Replace wiring between C-17, C-14 of the control board and terminals A+B of the K2 relay.

YES

Is voltage leaving the K2 anode relays on terminals 4+6?

Replace the K2 anode relay.

YES

Are 10+ amps present during the F3 fault alarm?

Run test cook cycles to see if fault repeats (page 10). If not, clear faults. Did fault repeat?

YES

Energize the magnetron circuit from Test Mode (page 16) and test for control voltage to the anode relay. Is 24 VDC present on pins C-17 and C-14 on the control board?

Test the high-voltage diodes (page

29). Are the high-voltage diodes functioning properly?

Replace the magnetron(s).

YES

Inspect/Replace wiring between K2 relay terminal 4 and T1-1 and between K2 relay terminal 6 and T2-3 (U.S. 240) / T2-2 (U.S. 208 or International) on the high-voltage transformers.

Energize the magnetron circuit from Test Mode (page 16) and test for control voltage on the K2 anode relay. Is 24VDC present on terminals A+B?

Remove and inspect the magnetrons for discolored antennas or waveguide contaminants. Any defects found?

Page 62

40 TROUBLESHOOTING

Troubleshooting:

F4: MONITOR (Door Monitor Defective)

YES

Is the F3 or, if applicable, the F4 fuse blown?

YES

Disconnect oven from power supply and then reconnect. The fault should clear.

Replace the F3 or, if applicable, the F4 fuse.

Are the switches opening in the correct sequence (P, S, M)? To access

TEST MODE or for

info on status indicators, see page 16.

Troubleshooting:

F5: MAG TEMP (Magnetron Over Temperature)

YES

Fault message should disappear.

Replace the control board.

Verify wiring. If necessary, replace the cooling fans.

Open the top cover, place the oven in

TEST MODE and test the magnetrons

(see page 16). Are the magnetron cooling fans operating?

Correct wiring/ replace the thermostats.

YES

Are the switches closing in the correct sequence (M, S, P)?

Remove the debris or reposition the oven away from obstruction.

YES

Do the magnetrons pass testing in the

TEST MODE? See page 16.

Is the airpath into the electrical compartment blocked or clogged with debris? Check the cooling fan finger guards and filter on the back panel.

YES

Verify wiring to magnetrons, and verify magnetron thermostats are not open. Are wiring and thermostats ok?

Replace the magnetron(s) and test again in

TEST MODE. Do the magnetrons pass

testing?

YES

Adjust the door switches. See page 24 for instructions. From the cooling down or off screen, press and hold the Info key for 5 seconds to reset the oven. The fault should clear.

Page 63

TROUBLESHOOTING

Troubleshooting:

F6: EC TEMP (Electrical Compartment Temperature High)

YES

Is the oven in an area of moderate temperature (120ºF (49ºC) or cooler)?

YES

Are both cooling fans rotating?

Relocate oven to cooler area.

YES

Check for obstructions in the airflow and remove them and clean the filter.

YES

Replace defective component.

Troubleshooting:

F7: THERMO (RTD Open)

YES

Is the RTD properly connected to the control board? (See page 49 for schematic.)

Correct wiring.

YES

Correct connection.

Is the wire harness properly connected? Check cooling fan thermostat and cooling fans. (See page 49 for schematic.)

Move oven to open area or remove items that are in close proximity.

Replace I/O Control Board.

Replace the RTD.

Does the oven have room to ventilate? See page 1 for standard clearances; 4-5 for openheat source clearances.

Is the RTD open?

Using an Ohmmeter, measure at the control board. The RTD should measure approximately 109 Ohms at 75

ºF

(24ºC)

. See page 33 for complete ohm temperature chart.

Page 64

42 TROUBLESHOOTING

YES

Replace the control board.

Correct wiring.

YES

Troubleshooting:

F8: HEAT LOW

YES

Is the high-limit thermostat tripped?

Are both blower motors moving air? Check in

TEST MODE

- see page 16.

YES

Reset (page 32) and determine why it tripped – excess grease buildup, etc.

See page 37 to troubleshoot F1: BLOWER (Blower Running Status Bad)

Is the solid state relay defective or damaged?

Is the heater defective? Check in

TEST MODE

- see page 16.

Replace defective heater.

Verify the solid state relay is not shorted across output.

Replace the solid state relay.

Is the wiring from the solid state relay to the control board OK? (See page 49 for schematic.)

Troubleshooting:

F9: CC TEMP (Cook Cavity Temperature High)

If this fault frequently occurs,

- Ensure the oven is cleaned daily (see pages 7-8).

- Determine if large amounts of grease laden food are being cooked, and if so, recommend smaller portions be cooked per cook cycle.

Page 65

TROUBLESHOOTING

Troubleshooting: No Keypad Input

YES

Replace the keypad. If the problem persists, replace the control board.

Is the keypad cable properly connected to the control board?

Correct wiring.

Non-Fault Code Troubleshooting

This section provides troubleshooting tips for issues that may occur independently of an oven fault.

Correct wiring. If wiring is damaged, replace door switch(es).

Replace the door switch(es).

YES

Refer to troubleshooting procedures on page 40.

Troubleshooting:

“Cook Door Open”Message when Door is Closed

Is “F4 MONITOR” fault present in the fault log?

Loosen the two switch bracket screws. With the door closed, position the bracket so that the switch actuator is just engaging the switch levers. Open and close the door. Are door switches freely opening and closing?

Tighten the switch bracket screws.

Verify the action of the switch actuators. When the door closes, do the actuators engage the switches?

YES

Adjust the counterbalance assembly (page

24). Is issue resolved?

Refer to page 24 for proper adjustment steps. The opening order must be P, S, M.

YES

Is the wiring from the door switches to control board OK?

Replace the counter-balance assembly.

Page 66

44 TROUBLESHOOTING

Troubleshooting:

No Display – Screen is Blank

YES

Does the keypad beep when a key is pressed?

Is wiring from the control board to the display OK?

Is pin 1 on the J7 connector receiving 5 VDC? (see schematic, page 49)

YES

Replace the display.

YES

Is the power supply output 24 VDC?

YES

Verify 5 VDC is present on pin 1 of the J7 connector. If not, replace the control board.

Is the control board receiving correct VDC?

Verify voltage on pin 2 of the J7 connector is 24 VDC (see schematic, page 49).

Replace the fuses.

Check wiring from the power supply to the control board. Correct wiring if necessary.

Replace the control board.

Correct wiring. If ribbon cable is damaged, replace the keypad.

Is the power supply receiving power?

Replace the power supply.

Page 67

TROUBLESHOOTING

YES

Is the food item in the correct starting state (e.g., frozen, fresh, etc.)?

Ensure the food item is being properly stored/prepared before cooking.

YES

Place the oven rack in correct position.

Is the oven rack positioned correctly (upper vs. lower position)?

YES

Ensure that the correct amount is being cooked not more or less than the recipe specifies.

Is the correct amount of food (portion) being cooked?

Ensure that the food item is properly prepared.

YES

Is the food item being prepared correctly and consistently? For example, bread cuts are straight and not “V” cuts, meat is sliced at correct thickness, pizza dough is correct consistency, etc.

Is the menu part number and revision correct? Verify with customer or contact TurboChef Customer Service.

YES

Are there any fault codes present? See page

35.

Are there any fault codes present? See page

35.

YES

Replace the control board.

Contact Customer Service to obtain the correct menu and load it to the oven.

YES

Is the menu part number and revision correct? Verify with customer or contact TurboChef Customer Service.

Troubleshoot the fault(s) using the steps on pages 35-42.

YES

Troubleshooting:

Food Not Cooking Properly

Is the lower air diverter installed?

Install the lower air diverter and ensure it is in place after each cleaning.

YES

Troubleshoot the fault(s) using the steps on pages 35-42.

Does the problem occur EVERY time the food item is cooked?

Does the problem occur for all programmed recipes? For example, are all recipes undercooked/overcooked/etc.?

YES

Page 68

46 TROUBLESHOOTING

Troubleshooting:

“Read Fail” Message When Loading Menu

Smart Card

USB Device

Did you use a smart card or USB device?

YES

Verify the USB device is securely attached to the USB port on the oven.

Replace the card reader/ USB port. If the problem persists, replace the control board.

Is the connection from USB port to control board OK?

Ensure the cable connecting the USB port to the control board is securely attached and not damaged.

YES

Name the file “menudata.bin” and store it in a top-level folder named “TC_Menus”.

Is the USB device securely attached to the oven?

Is the file named correctly (menudata.bin) and in the correct location (TC_Menus)?

If the menu card was created by TurboChef, obtain a new menu card by contacting customer service at

800.90

TURBO or +1 214-379-6000.

YES

Replace the card reader. If the problem persists, replace the control board.

Ensure the cable connecting the reader to the control board is securely attached and not damaged.

Is the connection from smart card reader to control board OK?

No backup copy

Does a backup copy of the menu work?

Page 69

TROUBLESHOOTING

Troubleshooting:

“Write Fail” Message When Loading Menu

Smart Card

USB Device

Are you trying to write to a smart card or USB device?

YES

Verify the USB device is securely attached to the USB port on the oven.

Is the connection from USB port to control board OK?

Ensure the cable connecting the USB port to the control board is securely attached and not damaged.

Try writing to a new smart card. Was the write successful?

YES

Replace the card reader. If the problem persists, replace the control board.

Ensure the cable connecting the reader to the control board is securely attached and not damaged.

Is the connection from smart card reader to control board OK?

On the USB device, create a top-level folder named “TC_Menus”.

YES

Does the USB device contain a top-level folder named “TC_Menus”?

Is the USB device securely attached to the oven?

Replace the card reader/ USB port. If the problem persists, replace the control board.

Page 70

48 TROUBLESHOOTING

Troubleshooting:

“Defective Media” Message When Oven is

Plugged in or Restarted

YES

Does the message prevent the oven from reaching the “Oven Off/ Cooling Down” screen?

Check for microwave leakage. If no leakage is found, replace the control board.

YES

Operate the oven as you would normally.

Unplug the oven and then plug it back in. Did this fix the problem?

Page 71

Oven Schematic

Page 72

Page 73

OVEN SCHEMATIC

Figure 39: i5 Oven Schematic

CONTROL BOARD

SEE CONTROL BOARD

LISTING FOR PART

NUMBER

3 2 1

Cable, Smart Card Reader

100182

CON-7005

i5-9247

A18 - TOP BLOWER 0 -10 VDC (J2-1) / RED

A17 - BOT. BLOWER 0 - 10 VDC ( J1-1) / YELLOW

C16 - K7-B MAG FAN RELAY INPUT (-) / WHITE

C13 - K1-B FILAMENT RELAY INPUT (-) / WHITE

A9 - RTD -1 INPUT / ORANGE

A8 - RTD - 2 INPUT / ORANGE

A7 - RTD - 3 INPUT / RED

A5 - VOLTAGE MODULE GND. / BLACK

B17 - RELAY COMMON +24VDC (A) / RED

B16 - K8 STIRRER RELAY INPUT (-) / WHITE

B10 - BOT BLOWER STATUS OK (J1-5) / BLUE

B8 - BOT BLOWER GND (J1-2 & 4) / BLACK

B7 - TOP BLOWER GND (J2-2 & 4) / BLACK

B2 - BOT BLOWER ENABLE (J1-3) / WHITE

B1 - TOP BLOWER ENABLE (J2-3) / WHITE

C22 - K5-B2 SSR RELAY (B-4) / WHITE C21 - K4-A2 SSR RELAY (A-2) / WHITE

C20 - SPEAKER (+) / RED

C19 - +24VDC INPUT (+V) / RED

C17 - MAG OT +24VDC /RED

C14 - K2-B ANODE RELAY INPUT (-) / WHITE

C12 - MAG OT STATUS / WHITE

C11 - K3-B MONITOR STATUS (-) / ORANGE

C10 - DS PRIMARY N.O. INPUT / WHITE

C9 - DS SECONDARY N.O. INPUT / WHITE

C8 - -24VDC RETURN (-) BLACK

C6 - DS MONITOR & SEC. COMMON / BLACK

C4 - K6-B VOLTAGE RELAY INPUT (-) / WHITE

C1 - TOP BLOWER STATUS OK (J2-5) / GRAY

3 2 1

C7 - SPEAKER (-) / BLACK

C5 - DS PRIMARY COMMON / BLACK

C3 - VOLT MODULE INPUT / RED

TFT DISPLAY

i5-3207

3 PHASE

WYE

100546

5 WIRE INPUT

380-415VAC

50HZ

A3 - A4 A2 - A3

102012

C-10

C-5

C-9

C-11

C-6

i5-9040

i5-9042

QC12

1 = (Common +), Red 2 = K1 (Filament), White 3 = K2 (Mags), White 4 = K3 (Monitor), Orange 5 = K6 (Volt), White

1 = Bottom Blower 0-10v, Yellow (A-17) 2 = Bottom Blower Enable, White, (B-2) 3 = Top Status OK, Gray, (C-1) 4 = Top Blower 0-10v, Red, (A-18) 5 = Top Blower Enable, White, (B-1) 6 = Bottom Status OK, Blue, (B-10)

QC11

456

10 = Not Used

Blower Motor Test Points

6 = K7 (Mag Fan), White 7 = K8 (Stirrer), White 8 = K4 (SSR), White 9 = K5 (SSR), White

C-20

C-7

Relay Test Points

NOTE; VOLTAGE MODULE NOT PRESENT FOR INTERNATIONAL MARKET OVENS

100546

TC3-0433

C-19

C-8

C-3

A-5

104155

100446

3 PHASE

DELTA

4 WIRE INPUT

230VAC

50HZ

THERMOSTAT

101211

VOLTAGE MODULE

100783

RED

BLACK

208/240VAC

60HZ

NEMA 15-30P

EC FAN

102086

BLUE

(YELLOW)

(BLUE)

BLUE

BROWN

BLUE

BROWN

L1 (F1)

JUMPER

i5-9312

JUMPER USED FOR SINGLE PHASE ONLY

NEUTRAL (F2-1)

L3 (F3-1)

100546

BLUE

BROWN

NEUTRAL (K6-7)

NEUTRAL (K3-7)

BROWN

BLUE

BROWN

B-17

BLUE

4 6

RED

NEUTRAL (HX-2)

NEUTRAL (HX-1)

EMI-L2 (K5-B1)

1110

SINGLE PHASE

3 WIRE INPUT

230VAC

50HZ

IEC 3-PIN

CAPACITOR/DIODE

700-1214

EMI-L1 (K4-A1)

208/240VAC

60HZ

L 2

L 1

NEMA 6-50P

ORANGE

BROWN

ORANGE

BLUE

ORANGE

BROWN

BLUE

i5-9390

BLUE

DIODE

BLUE

CHANGED MAG COOLING FAN CONNECTIONS FROM 1 TO 4 ON K7 RELAY,

GENERAL UPDATES, AND PART NUMBER ADDITIONS

REMOVED F4 FUSE CIRCUIT, MOVED LV SUPPLY WIRE FROM F4 TO F3 TERMINAL,

HV TRANSFORMERS

60HZ (NON JAPAN) NGC-3062-1 50HZ (NON JAPAN) NGC-3062-2 50/60HZ JAPAN NGC-3062-3

NOTE: ONLY THE NGC-3062-1 AND THE NGC-3061-1 HAVE 3 PRIMARY TAPS, ALL OTHER TRANSFORMERS HAVE 2 PRIMARY TAPS

NOTE: JUMPER ON CAPACITORS FOR 50HZ OPERATION ONLY (BETWEEN TERMINALS 1 & 3)

FILAMENT TRANSFORMERS

60HZ (NON JAPAN) NGC-3061-1

50HZ (NON JAPAN) NGC-3061-2 50/60HZ JAPAN NGC-3061-3

JUMPER

REPLACED F3 FUSE WITH 20 AMP ATMR FUSE

100481

JUMPER

100481

GENERAL UPDATES

CAPACITORS

60HZ (NON JAPAN 0.91uf) NGC-3020 50HZ (ALL 50HZ OVENS) NGC-3020-2 60HZ JAPAN (0.85uf) 100207

100083

NGC-3015

100083

NGC-3015

102070

HX ELEMENTS (2)

(3000 WAT T EACH)

(14.4 OHMS)

i5-9317

HX 1

HX 2

TURBOCHEF TECHNICAL SUPPORT

800.908.8726 (USA)

+214.379.6000 (INTERNATIONAL)

SCHEMATIC, i5

MULTIPHASE, 230, 380-415 VAC, 50 HZ

MULTIPHASE, 208 - 240 VAC, 60 HZ

B-17

+ - + 1 2 3 4

C-21

C-22

SOLID STATE

RELAY

NGC-3005

GREG HAUN

MANUAL RESET

HIGH TEMP LIMIT

102075

10/16/08

ECN 0810029

11/6/08

ECN 0811003

09/17/09

ECN 0909029

K1, K2, K3, K7, K8 RELAY DETAIL

101273

K6 RELAY DETAIL

101272

HHC-6517

F1: 12 AMPS ATMR 100592 F2: 12 AMPS ATMR 100592 F3: 20 AMPS ATMR 100599

ALL FUSES ARE CLASS CC

Page 74

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left blank.

Page 75

Appendix - Replacing Oven Components

Page 76

Page 77

A-1

APPENDIX - REPLACING OVEN COMPONENTS

To Replace This... First Remove This...

Item Part Number

No Covers (Page A-3)

No CoversOpen Top (Page A-5)

Top Cover (Page A-7)

Left Side Cover (Page A-9)

Right Side Cover (Page A-11)

Items Obstructing Access

Blower Motor (Bottom) I5-9042



EMI Filter, EMI Fil Brkt

Blower Motor (Top) I5-9040



EMI Filter, EMI Fil Brkt

Blower Wheel (Bottom) 103550



Blower Motors

Blower Wheel (Top) 103551



Blower Motors

Capacitor, High-Voltage 100232



Capacitor Clamps

Capacitor Clamp 100134



Catalytic Converter I5-9066



RTD and Heater Assy

Control Board I5-3208-1



Cooling Fan (Exterior) TC3-0433



Filter, Filter Brkt, Finger Guard

Cooling Fan (Interior) TC3-0433



Cooling Fan Finger Guard 100086



Filter, Filter Bracket

Cooling Fan, Magnetron 100083



Cooling Fan (Magnetron) Bracket I5-9263



Diodes, High-Voltage 100481



Display, TFT I5-3207



Display, VFD OBSOLETE



Door Assembly* I5-9308



Door Gasket I5-9309



Shunt Plate

Door Handle I5-9253



Door Skin

Door Skin I5-9109



Door

Drain Pan OBSOLETE



Drain Pan, Recessed I3-9252



Lower Front Panel, Covered

EMI Filter 100546



EMI Filter Bracket I5-9257



Filter, Air I5-9039



Filter Bracket I5-9060



Firmware Upgrade, TFT Display I5-3206



Firmware Upgrade, VFD Display I5-3205



Fuse, F1, 12-amp 100592



Fuse, F2, 12-amp 100592



Fuse, F3, 12-amp 100592



Fuse, F3, 20-amp 100599



Fuse, F4, 12-amp 100592



Fuse Holder 103548



Fuses

Hand Grip I5-9256



Heat Shield/Support Bracket I5-9224



Heat Slinger 102708



Blower Motors

Heater Assembly i5-3214



RTD

Heater, Helical i5-9381



RTD, Heater Plate

Helper Spring, Interlock Switch (Left) i5-9397



Helper Spring, Interlock Switch (Right) i5-9397



Comprehensive Table of Oven Components

DANGER: Before replacing any oven component, ensure the oven is removed from any power source. Replacing a component while the oven is plugged in can result in serious injury or death.

NOTE: For hardware, see the illustrations contained in this appendix.

* See page A-12 through A-13 for removing door, hinge components, magnetrons, magnetron thermostats, or waveguides.

Page 78

To Replace This... First Remove This...

Item Part Number

No Covers (Page A-3)

No CoversOpen Top (Page A-5)

Top Cover (Page A-7)

Left Side Cover (Page A-9)

Right Side Cover (Page A-11)

Items Obstructing Access

Hinge, Bracket, Slide, LHS I5-9196

 

Door, Switches

Hinge, Bracket, Slide, RHS I5-9195

 

Door, Switches

Hinge, Cam, Weldment, LHS I5-9313

 

Door, Switches

Hinge, Cam, Weldment, RHS I5-9314

 

Door, Switches

Hinge, Guide, Switch Slide, Lower I5-9316

 

Door, Switches

Hinge, Guide, Switch Slide, Upper I5-9315

 

Door, Switches

Hinge, Gusset, LHS I5-9178

 

Door, Switches

Hinge, Gusset, RHS I5-9179

 

Door, Switches

Hinge Module, Base I5-9193

 

Door, Switches

Hinge, Torsion Bar I5-9144

 

Door, Switches

Hinge, Weldment, Countrblnce Bracket, LHS I5-9326

 

Door, Switches

Hinge, Weldment, Countrblnce Bracket, RHS I5-9327

 

Door, Switches

Interlock Switch (Monitor) 102012



Interlock Switch (Primary) 102012



Interlock Switch (Secondary) 102012



Jetplate (Bottom) I5-3200



Rack

Jetplate (Top) I5-3204



Keypad I5-9247



Lower Front Panel OBSOLETE



Drain Pan

Lower Front Panel, Covered I5-9282



Magnetron (Left)* NGC-3015

 

Magnetron (Right)* NGC-3015

 

Motor Controller 100446



Power Cord I5-9127



Power Supply 101211



Pwr Supply Brkt

Power Supply Bracket I5-9280



Rack I5-9168



Rack Support I5-9165



Rack

Relay (K1 - Filament) 101273



Relay (K2 - Anode) 101273



Relay (K3 - Monitor) 101273



Relay (K6 - Voltage) 101272



Relay (K7 - Mag Fan) 101273



Relay (K8 - Stirrer) 101273



Relay Bracket I5-9261



Relay, Solid State (K4/K5 - Heaters) 101286



RTD, Cook Cavity HHC-6517



Shunt Plate Assembly I5-9307



Door

Smart Card/USB Port CON-7005



Control Board

Speaker 104155



Stirrer I5-9154



Top Jetplate

Stirrer Coupling Hub 104132



Stirrer Motor

Stirrer Coupling Spider Insert 104306



Stirrer Motor

Stirrer Motor 100884



Stirrer Mtr Bracket

Stirrer Motor Bracket I5-9075



* See page A-12 through A-13 for removing door, hinge components, magnetrons, magnetron thermostats, or waveguides.

A-2

APPENDIX - REPLACING OVEN COMPONENTS

Page 79

APPENDIX - REPLACING OVEN COMPONENTS

A-3

Figure Reference #

Item Description Item Part Number Hardware Description Hardware Part Number(s)

1 Door Assembly* I5-9308 Screw, #8-32 x 3/8, PFH, 100 Deg, SS 102809 (qty 6)

2 Door Gasket I5-9309 None None

3 Door Handle I5-9253 Screw, 1/4-20 x .25 lg, Serrated Hex 102947 (qty 4)

4 Door Skin I5-9109 Screw, 6-32 x .38, PFH, 100 Deg, SS 101430 (qty 9)

5 Drain Pan, Recessed I3-9252 None None

6 Filter, Air I5-9039 None None

7 Filter Bracket i5-9060

Screw, Sh Mtl #8 x 1/2, Serrated PHTRH Plug, Knockout, 1/2”, Black

A) 101688 (qty 6) B) 101191 (qty 1)

8 Hand Grip I5-9256 Screw, #8 X 1/2, Serrated, PHTRH, Black Oxide 101691 (qty 2)

9 Jetplate (Bottom) I5-3200 Screws and Mounting Clips, Fast Lead I5-3201

Replacing Items - No Cover Removal Required (Figures A-1, A-2)

CAUTION: Before removing/installing any component, make sure it is disconnected from the wire harness (where applicable).

NOTE: Hardware listed is required for installing component to oven.

To Replace This... First Remove This...

Item Part Number

No Covers (Page A-3)

No CoversOpen Top (Page A-5)

Top Cover (Page A-7)

Left Side Cover (Page A-9)

Right Side Cover (Page A-11)

Items Obstructing Access

Stirrer Shaft I5-9151



Stir Mtr, Brkt, Top Jetplate, Stirrer

Stirrer Shaft, Support I5-9152



Stir Mtr, Brkt, Top Jetplate, Stirrer

Thermostat, Cooling Fans 102086



Thermostat, High-Limit 102075



Filter, Filter Bracket

Thermostat, Magnetron (Left)* 102070

 

Magnetron (Left)

Thermostat, Magnetron (Right)* 102070

 

Magnetron (Right)

Transformer, Filament NGC-3061-1



Transformer, High-Voltage NGC-3062-1



Vent Catalyst Foil Pack RWD-9191



Vent Tube Cover

Vent Tube Cover I5-9209



Heat Chnl Wldmt

Voltage Sensor 100783



Waveguide (Left)* I5-3210

 

Mag, FT/Diode Bracket, Capacitor, WG Gasket

Waveguide (Right)* I5-3210

 

Mag, FT/Diode Bracket, Capacitor, WG Gasket

Waveguide Gasket (Left)* I5-9331

 

Mag, FT/Diode Bracket, Capacitor, WG Gasket

Waveguide Gasket (Right)* I5-9331

 

Mag, FT/Diode Bracket, Capacitor, WG Gasket

Weldment, Heat Channel, Vent Tube NGC-1397



* See page A-12 through A-13 for removing door, hinge components, magnetrons, magnetron thermostats, or waveguides.

Page 80

APPENDIX - REPLACING OVEN COMPONENTS

Figure A-1: No Cover Removal Required

2 3 4

Figure Reference #

Item Description Item Part Number Hardware Description Hardware Part Number(s)

10 Jetplate (Top) I5-3204 None None

11 Lower Front Panel, Covered i5-9282 None None

12 Rack I5-9168 None None

13 Rack Support I5-9165 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 101688 (qty 4)

14 Shunt Plate Assembly I5-9307 Screw, 6-32 x .38, PFH, 100 Deg, SS 101430 (qty 9)

15 Stirrer I5-9154

A) Screw, #10-32 x 1/2, PPH, SS B) Washer, Lock, #10 Ext Tooth, Cres

A) 101460 (qty 1) B) 102260 (qty 1)

16 Vent Catalyst Foil Pack RWD-9191 None None

17 Vent Tube Cover I5-9209 Screw, #6 x 1/2, PPHD, Drill Point, SS 101687 (qty 2)

18 Weldment, Heat Chnl, Vent Tube NGC-1397 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 101688 (qty 6)

A-4

1817

Figure A-2: Door Assembly Detail

Page 81

APPENDIX - REPLACING OVEN COMPONENTS

A-5

Replacing Items - Opening Top Cover Required (Figure A-3)

DANGER: Before replacing any oven component, ensure the oven is removed from any power source. Replacing a component while the oven is plugged in can result in serious injury or death.

CAUTION: Before removing/installing any component, make sure it is disconnected from the wire harness (where applicable).

NOTE: Hardware listed is required for installing component to oven.

To open the top cover:

1. Open the oven door.

2. The top cover is secured to the heat shield via 2 sheet metal screws (above the oven door). Remove these screws.

3. Open the top cover.

4. Secure the support arms in place.

Figure A-3: Opening Top Cover Required

Page 82

A-6 APPENDIX - REPLACING OVEN COMPONENTS

Figure Reference #

Item Description Item Part Number Hardware Description Hardware Part Number(s)

1 Cover, Top I5-9243 Screw, #10-32 x 3/8 lg, PFLH, 100 Deg, SS 101401 (qty 2)

2 Fuse, F1, 12-amp 100592 None None

3 Fuse, F2, 12-amp 100592 None None

4 Fuse, F3, 12-amp

†

100592 None None

5 Fuse, F3, 20-amp

†

100599 None None

6 Fuse, F4, 12-amp

†

100592 None None

7 Fuse Holder 103548 Screw, #8-32 x 3/8, PPHD, Int Sems, SS 102921 (qty 4)

8 Heat Shield/Support Bracket I5-9224 Screw, Torx Head, Sh Mtl, 3/8, Cres 102752 (qty 2)

9 Keypad* I5-9247 None None

10 Power Supply 101211 Screw, M3 x 8mm, Sems, PPHD, Cres 103444 (qty 3)

11 Power Supply Bracket I5-9280 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 101688 (qty 2)

12 Relay (K1 - Filament) 101273 Nut, Keps, Hex, #6-32, Ext Tooth, Cres 102961 (qty 2)

13 Relay (K2 - Anode) 101273 Nut, Keps, Hex, #6-32, Ext Tooth, Cres 102961 (qty 2)

14 Relay (K3 - Monitor) 101273 Nut, Keps, Hex, #6-32, Ext Tooth, Cres 102961 (qty 2)

15 Relay (K6 - Voltage) 101272 Nut, Keps, Hex, #6-32, Ext Tooth, Cres 102961 (qty 2)

16 Relay (K7 - Mag Fan) 101273 Nut, Keps, Hex, #6-32, Ext Tooth, Cres 102961 (qty 2)

17 Relay (K8 - Stirrer) 101273 Nut, Keps, Hex, #6-32, Ext Tooth, Cres 102961 (qty 2)

18 Relay Bracket I5-9261 Screw, #8 x 3/8 PH Mod Truss, Cres 101682 (qty 4)

19 Relay, Solid State (K4/K5 - Heaters) 101286 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 101688 (qty 2)

* NOTE: Additional keypad detail on Figure A-6, page A-8.

† NOTE:i5 ovens with serial numbers after 00501 are not equipped with 12-amp F3 and F4 fuses, instead

they are equipped with a single 20-amp F3 fuse. Older oven models may still be equipped with the 12-amp F3 and F4 fuses.

Page 83

APPENDIX - REPLACING OVEN COMPONENTS

A-7

Figure A-4: Removing Top Cover Required

Replacing Items - Removing Top Cover Required (Figures A-4, A-5, A-6)

DANGER: Before replacing any oven component, ensure the oven is removed from any power source. Replacing a component while the oven is plugged in can result in serious injury or death.

CAUTION: Before removing/installing any component, make sure it is disconnected from the wire harness (where applicable).

NOTE: Hardware listed is required for installing component to oven.

To remove the top cover:

1. Open the top cover (see page A-5 for instructions).

2. Remove the hinge screws located near the back of each side of the top cover.

3. Detach the support braces from the oven frame. (The should remain attached to the top panel.)

CAUTION: When detaching the support braces, be sure to support the top cover to prevent it from collapsing onto the components in the electrical compartment.

4. Remove the top panel and place it somewhere safe.

CAUTION: The top cover has critical components attached. Handle it carefully.

768

Figure A-5: Stirrer Motor and Assembly Detail

Page 84

A-8

APPENDIX - REPLACING OVEN COMPONENTS

Figure Reference #

Item Description Item Part Number Hardware Description Hardware Part Number(s)

1 Capacitor, High-Voltage 100232 None None

2 Capacitor Clamps 100134 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 101688 (qty 2)

3 Control Board I5-3208-1 Nut, Keps, Hex, #6-32, Ext Tooth, Cres 102961 (qty 4)

4 Cooling Fan (Exterior) TC3-0433 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 101688 (qty 2)

5 Cooling Fan (Interior) TC3-0433 Screw, #8-32 x 2 1/2 Lg, PPHD, SS 101661 (qty 2)

6 Cooling Fan Finger Guard 100086 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 101688 (qty 2)

7 Cooling Fan, Magnetron 100083

A) Screw, #10-32 x 2 1/4, PPH, SS B) Washer, Lock, #10 Int Tooth, Cres

A) 101484 (qty 3) B) 102290 (qty 3)

8 Cooling Fan (Magnetron) Bracket I5-9263 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 101688 (qty 4)

9 Diode, High-Voltage 100481 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 101688 (qty 2)

10 Display, TFT I5-3207 Nut, Keps, Hex, #4-40, Ext Tooth 102960 (qty 4)

11 Motor Controller 100446 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 101688 (qty 4)

12 Smart Card/USB Port CON-7005

A) Standoff, Round, .12 ID, .25 OD x .375” B) Nut, Keps, Hex, #4-40, Ext Tooth

A) 101923 (qty 4) B) 102960 (qty 4)

13 Stirrer Coupling Hub (qty 2 per oven) 104132 Set Screw (Provided) None

14 Stirrer Coupling Spider Insert 104306 None None

15 Stirrer Motor 100884 Screw, M4 x 0.7 x 8, PPHD, Int Tooth, SS 101672 (qty 2)

16 Stirrer Motor Bracket I5-9075 Screw, M4 x 0.7 x 8, PPHD, Int Tooth, SS 101672 (qty 2)

17 Stirrer Shaft I5-9151 None None

18 Stirrer Shaft, Support I5-9152 None None

19 Thermostat, Cooling Fans 102086 Screw, #6 x 1/2, PPHD, Drill Point, SS 101687 (qty 2)

20 Thermostat, High-Limit 102075 Screw, M4 x 0.7 x 8, PPHD, Int Tooth, SS 101672 (qty 2)

21 Transformers, Filament NGC-3061-1 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 101688 (qty 4)

22 Transformers, High-Voltage NGC-3062-1 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 101688 (qty 4)

Figure A-6: Top Cover Detail

Page 85

APPENDIX - REPLACING OVEN COMPONENTS

A-9

Figure Reference #

Item Description Item Part Number Hardware Description Hardware Part Number(s)

1 Blower Motor (top) I5-9040 Nut, 1/4 - 20, Serr Hex Flange, Plated 100906 (qty 4)

2 Blower Motor (bottom) I5-9042 Nut, 1/4 - 20, Serr Hex Flange, Plated 100906 (qty 4)

3 Blower Wheel (top) 103551 None None

4 Blower Wheel (bottom) 103550 None None

5 Cover, Left Side I5-9301 Screw, #8 Serr, PHD Truss, Black Oxide 101691 (qty 5)

6 EMI Filter 100546 Screw, M5 x 8, PPHD, Sems, SS 101707 (qty 4)

7 EMI Filter Bracket I5-9257 Screw, #10-32 x 3/4 lg, PPH Sems, Int Th 102937 (qty 2)

8 Heat Slinger 102708 None None

9 Helper Spring, Interlock Switch* i5-9397 None None

10 Interlock Switch, Primary* 102012 Screw, #4-40 x 1”, PPH, Sems 102903 (qty 2)

11 Mounting Bracket, Interlock Switch* I5-9272 Screw, #10-32 x 3/4 lg, PPH Sems, Int Th 102937 (qty 2)

12 Power Cord I5-9127 None None

13 Voltage Sensor 100783 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 101688 (qty 1)

Replacing Items - Removing Left Side Cover Required (Figures A-7, A-8)

DANGER: Before replacing any oven component, ensure the oven is removed from any power source. Replacing a component while the oven is plugged in can result in serious injury or death.

CAUTION: Before removing/installing any component, make sure it is disconnected from the wire harness (where applicable).

CAUTION: Be careful to not tear the insulation when servicing components. Always reset the insulation properly before reinstalling the side panel.

NOTE: Hardware listed is required for installing component to oven.

To remove the left side cover, remove the screws securing the panel to the oven frame. To re-install the left side cover, you may need to open the top cover (see page A-5).

* NOTE: For more interlock switch detail, see Figure A-11, page A-13.

Page 86

A-10 APPENDIX - REPLACING OVEN COMPONENTS

Figure A-7: Removing Left Side Cover Required

Figure A-8: Blower Motor Assembly

3 8

Page 87

APPENDIX - REPLACING OVEN COMPONENTS

A-11

Figure A-9: Removing Right Side Cover Required

Figure Reference #

Item Description Item Part Number Hardware Description Hardware Part Number(s)

1 Catalytic Converter I5-9066 None None

2 Cover, Right Side I5-9302 Screw, #8, Serr PPHD, Truss, Black Oxide 101691 (qty 5)

3 Heater Assembly

†

I5-3214 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 101688 (qty 10)

4 Heater, Helical (qty 2 per oven) i5-9381 Screw, #8-32 x 3/8, PPHD, INT SEMS, SS 102921 (qty 3 per heater)

5 Helper Spring, Interlock Switch* i5-9397 None None

6 Interlock Switch - Monitor* 102012 Screw, #4-40 x 1”, PPH, Sems 102903 (qty 2)

7 Interlock Switch - Secondary* 102012 Screw, #4-40 x 1”, PPH, Sems 102903 (qty 2)

8 Mounting Bracket, Interlock Switch* I5-9272 Screw, #10-32 x 3/4 lg, PPH Sems, Int Th 102937 (qty 2)

9 RTD, Cook Cavity HHC-6517 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 101688 (qty 2)

Replacing Items - Removing Right Side Cover Required (Figure A-9)

DANGER: Before replacing any oven component, ensure the oven is removed from any power source. Replacing a component while the oven is plugged in can result in serious injury or death.

CAUTION: Before removing/installing any component, make sure it is disconnected from the wire harness (where applicable).

NOTE: Hardware listed is required for installing component to oven.

To remove the right side cover:

1. Remove the screws securing the panel to the oven frame.

2. Remove the right side cover.

* NOTE: For more interlock switch detail, see Figure A-11, page A-13.

† NOTE: The Heater Assembly service kit (i5-3214) is only used for replacing the older style finned

heater assembly. The service kit includes two Helical Heaters and the Heater Plate.

Page 88

A-12 APPENDIX - REPLACING OVEN COMPONENTS

Figure Reference #

Item Description Item Part Number Hardware Description Hardware Part Number(s)

1 Hinge, Bracket, Slide, LHS I5-9196 Nut, Keps, Hex, #8-32, Ext Tooth, Cres 102962 (qty 4)

2 Hinge, Bracket, Slide, RHS I5-9195 Nut, Keps, Hex, #8-32, Ext Tooth, Cres 102962 (qty 4)

3 Hinge, Cam, Weldment, LHS I5-9313 Washer, Nylon, Hingepin C0504 (qty 1)

4 Hinge, Cam, Weldment, RHS I5-9314 Washer, Nylon, Hingepin C0504 (qty 1)

5 Hinge, Guide Block, Top i5-9394 Nut, Keps, Hex, #8-32, Ext Tooth, Cres 102962 (qty 4)

6 Hinge, Guide Block, Bottom i5-9393 None None

7 Hinge, Gusset, LHS I5-9178 Nut, 1/4 - 20, Serr, Hex Flange, Plated Steel 100906 (qty 2)

8 Hinge, Gusset, RHS I5-9179 Nut, 1/4 - 20, Serr, Hex Flange, Plated Steel 100906 (qty 2)

9 Hinge Module, Base I5-9193 None None

10 Hinge, Torsion Bar I5-9144 Spacer, Adjustment Call TurboChef

11 Hinge, Weldmt, Ctrblnce Brkt, LHS I5-9326 Screw, 10-32 x 3/8 lg, PFLH, 100 Deg, SS 101401 (qty 3)

12 Hinge, Weldmt, Ctrblnce Brkt, RHS I5-9327 Screw, 10-32 x 3/8 lg, PFLH, 100 Deg, SS 101401 (qty 3)

13 Magnetron (Left) NGC-3015 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 101688 (qty 4)

14 Magnetron (Right) NGC-3015 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 101688 (qty 4)

15 Thermostat, Magnetron (Left) 102070 Screw, Sh Mtl, Drill Point, 6-32 x 3/8, PPHD, Zinc 101684 (qty 2)

16 Thermostat, Magnetron (Right) 102070 Screw, Sh Mtl, Drill Point, 6-32 x 3/8, PPHD, Zinc 101684 (qty 2)

17 Waveguide (Left) I5-3210 Nut, Keps, Hex, #10-32, Ext Tooth, Cres 102963 (qty 9)

18 Waveguide (Right) I5-3210 Nut, Keps, Hex, #10-32, Ext Tooth, Cres 102963 (qty 9)

19 Waveguide Gasket (Left) I5-9331 None None

20 Waveguide Gasket (Right) I5-9331 None None

Replacing Items - Removing/Opening Multiple Covers Required (Figures A-10, A-11)

DANGER: Before replacing any oven component, ensure the oven is removed from any power source. Replacing a component while the oven is plugged in can result in serious injury or death.

CAUTION: Before removing/installing any component, make sure it is disconnected from the wire harness (where applicable).

NOTE: Hardware listed is required for installing component to oven.

To remove the left side cover, see page A-9.

To remove the right side cover, see page A-11.

To open the top cover, see page A-5.

Page 89

APPENDIX - REPLACING OVEN COMPONENTS

A-13

Figure A-10: Removing/Opening Multiple Covers Required

Figure A-11: Counter Balance Assembly, Hinge, and Switch Detail

Page 90

For service or information:

WITHIN NORTH AMERICA CALL

Customer Service at 800.90TURBO or

OUTSIDE NORTH AMERICA CALL

+1 214-379-6000 or Your Authorized Distributor

Part Number: i5-9231 / Revision F / April 2010 Country Code: NA/EU

Global Operations

4240 International Pkwy, Suite 1 05 Carrollton, Texas 75007

USA

+1 214-379-6000 PHONE +1 214-379-6073

FAX

Customer Support

1-800-90

TURBO

+1 214-379-6000 turbochef.com

Turbochef I5 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual