TurboChef l D3 Service Manual

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Service Manual

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TurboChef Model D3 Ovens

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Steps before Operating Oven.

Customer Service Toll Free Number (888) 992-6624

P/N T0032 Rev A (2/00)

TABLE OF CONTENTS

Contents Page

IMPORTANT SAFETY INSTRUCTIONS - READ FIRST.......................................... 4, 5

RF INTERFERENCE CONSIDERATIONS .................................................................... 6

GROUNDING INSTRUCTIONS.....................................................................................6

POWER CORD REPLACEMENT..................................................................................6

SECTION 1 - INSTALLATION

1.1 Model Identification and Rating........................................................................7

1.2 Installation Instructions..................................................................................... 7

1.3 Specifications................................................................................................... 8

1.4 Oven Assembly................................................................................................ 9

SECTION 2 - OPERATING INSTRUCTIONS

2.1 Glossary of Common Terms.......................................................................... 11

2.2 Basic Operating Instructions.......................................................................... 12

2.3 Other Oven Operations.................................................................................. 13

2.4 Developing Cook Settings and Programming ................................................ 15

2.5 Control Panel Layout......................................................................................20

SECTION 3 – CLEANING AND SELF TEST

3.1 Basic Cleaning Procedures - Care and Cleaning...........................................21

3.2 Maintenance Mode Troubleshooting..............................................................33

3.3 Self Test and On-Line Error Messages.......................................................... 35

3.4 Self Test Flow Chart....................................................................................... 37

3.5 On-Line Flow Chart........................................................................................39

SECTION 4 – CONVECTION SYSTEM

4.1 Blower Motor Assembly..................................................................................40

4.2 Blower Motor Controller Tests........................................................................41

4.3 Blower Defective Messages........................................................................... 41

4.4 Blower Motor Controller Defective Messages ................................................ 42

4.5 Blower Operation ...........................................................................................45

4.6 Blower Wheel Replacement...........................................................................46

4.7 Heat Exchanger .............................................................................................47

4.8 Ceramic Insulator Replacement.....................................................................49

4.9 Heat Exchanger Defective Messages............................................................50

SECTION 5 - MICROWAVE SYSTEM

5.1 Measuring Microwave Radiation Leakage......................................................51

5.2 How to Turn Magnetrons On/Off for Testing..................................................52

5.3 Microwave Component Locations..................................................................53

5.4 Microwave Error Messages............................................................................55

5.5 Magnetron...................................................................................................... 56

5.6 High Voltage (HV) Magnetron Transformers..................................................57

5.7 High Voltage Diode........................................................................................ 58

5.8 High Voltage Capacitor.................................................................................. 60

5.9 Microwave Mode Stirrer................................................................................. 61

5.10 Magnetron Over-Temperature Switch............................................................ 61

5.11 RF Output Monitor Circuit...............................................................................62

5.12 Magnetron Power Verification........................................................................62

5.13 Waveguide Seal Installation...........................................................................64

SECTION 6 - COOK DOOR ASSEMBLY

6.1 Cook Door and Related Assemblies.............................................................. 66

6.2 Cook Door and Interlock Switch Adjustments................................................68

SECTION 7 - FILTER DOOR SWITCH LOCATION / ASSEMBLY..............................69

SECTION 8 - CONTROL

8.1 Electrical Enclosure Assembly.......................................................................70

8.2 Electrical Enclosure Diagnostic Message ...................................................... 71

8.3 Display and Keypad Assembly....................................................................... 71

SECTION 9 - MAG. FAN/COOLING FAN/TRANSFORMERS/DIODES/CAPS............ 72

SECTION 10 - TROUBLESHOOTING

10.1 Common Door Related Problems.................................................................. 74

10.2 Miscellaneous Problems................................................................................ 75

SECTION 11 - DIAGNOSTIC INFORMATION (INCLUDING SCHEMATICS)............. 77

SECTION 12 - LIMITED WARRANTY FOR “D” SERIES OVENS............................... 83

SECTION 13 – TECHNICAL APPENDIX

13.1 Appendix A – Oven Connection to Computer................................................ 84

13.2 Appendix B – Japanese Input Power Frequency Conversion........................85

13.3 Appendix C – Japanese Additional EMI Filter................................................ 86

13.4 Appendix D – T3 & T4 Filament Transformer 200-208 Voltage Selection...... 87

IMPORTANT SAFETY INSTRUCTIONS

WHEN USING ELECTRICAL APPLIANCES, BASIC SAFETY PRECAUTIONS SHOULD BE FOLLOWED, INCL UDING THE FOLLOWING:

WARNING - To reduce the risk of burns, electric shock, fire, injury to persons or

exposure to excessive microwave energy:

1. Read all instructions before using the appliance.

2. Read and follow the specific “PRECAUTIONS TO BE OBSERVED BEFORE AND DURING

SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY” found on page 5.

3. This appliance must be grounded. Connect only to properly grounded outlet. See “GROUNDING

INSTRUCTIONS” found on page 6.

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

5. Some products such as whole eggs and sealed containers - for example, closed glass jars - may

explode and SHOULD NOT be heated in this oven.

6. Use this appliance only for its intended use as described in the owner’s manual. DO NOT use

corrosive chemicals or vapors in this appliance. This type of oven is specifically designed to heat, cook, or dry food. It is NOT designed for industrial or laboratory use.

7. Children SHOULD NOT use this appliance.

8. DO NOT operate this appliance if it has a dam aged cord or plug, if it is not working proper ly, or if it

has been damaged or dropped. See “POWER SUPPLY CORD REPLACEMENT” found on page 6.

9. This appliance should be serviced only by qualified service personnel

10. DO NOT cover or block any openings on the appliance.

11. DO NOT store this appliance outdoors. DO NOT use this product near water - for exam ple, near a

kitchen sink, in a wet basement, or near a swimming pool, and the like.

12. DO NOT immerse cord or plug in water.

13. Keep cord away; from heated surfaces.

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

15. DO NOT use a water jet for cleaning.

16. See “Basic Maintenance Procedures - Care and Cleaning” provided in this manual.

17. To reduce the risk of fire in the oven cavity:

a) DO NOT overcook food. Carefully attend appliance if paper, plastic, or other combustible

materials are placed inside the oven to facilitate cooking. b) Remove wire twist-ties from paper or plastic bag in oven. c) If materials inside the oven should ignite, keep oven door c losed, turn oven off, and disconnect

the power cord, or shut off power at the fuse or circuit breaker panel. d) DO NOT use the cavity for storage purposes. DO NOT leave paper products, c ooking utensils , or

food in the cavity when not in use.

SAVE THESE INSTRUCTIONS

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PRECAUTIONS TO BE OBSERVED BEFORE AND DURING

SERVICING TO AVOID POSSIBLE EXPOSURE TO

EXCESSIVE MICROWAVE ENERGY

1. DO NOT attempt to operate this oven with the door open since open-door operation

can result in harmful exposure to microwave energy. It is important not to defeat or tamper with the safety interlocks.

2. DO NOT place any object between the oven front face and the door or allow soil or cleaner residue to accumulate on the sealing surfaces.

3. Make the following safety checks on all ovens to be serviced before activating the magnetron or other microwave source, and make repairs as necessary: a) Interlock operation. b) Proper door closing. c) Door (bent). d) Hinges and latches (broken or loosened). e) Door seals and sealing surfaces (arcing, wear, and other damage). f) Evidence of dropping or abuse.

4. 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 connection.

5. Any defective or mis-aligned components in the interlock, monitor, door seal, and microwave generation and transmission systems must be repaired, replaced, or adjusted by procedures described in this manual before the oven is released to the owner.

6. The oven SHOULD NOT be adjusted or repaired by anyone except properly qualified service personnel.

7. A microwave leakage check to verify compliance with the Federal Performance Standard MUST BE performed on each oven prior to release to the owner.

SAVE THESE INSTRUCTIONS

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RF INTERFERENCE CONSIDERATIONS

This oven generates radio frequency signals. This device has been tested and determined to be in compliance with applicable part 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 co mpatibility at the time of manufacture. However, some other equipment may exhibit sensitivity to signals below these limits resulting in interference with that equipment.

If your equipment experiences interference, the following steps should be considered:

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

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

3. If battery powered microphones are being affected, insure that the batteries are fully charged.

4. Keep sensitive equipment on electrically separate circuits, if possible.

5. DO NOT route intercom wires, microphone wires, or speaker cables near oven.

GROUNDING INSTRUCTIONS

This appliance MUST BE grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. This appliance is equipped with a cord having a grounding wire with a grounding plug. The plug must be plugged into an outlet that is properly installed and grounded.

WARNING - Improper use of the grounding can result in a risk of electric shock.

Consult a qualified electrician or serviceman if the grounding instructions are not completely understood, or if doubt exists as to whether the appliance is properly grounded.

DO NOT use an extension cord. If the power supply cord is too short, have a qualified electrician or serviceman install an outlet near the appliance.

POWER SUPPLY CORD REPLACEMENT

If the power supply cord is damaged, it MUST BE replaced by the manufacturer or its service agent or a similarly qualified person in order to avoid a hazard.

SAVE THESE INSTRUCTIONS

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SECTION 1 - INSTALLATION

1.1 MODEL IDENTIFICATION AND RATING

MODEL NUMBER, NAMEPLATE INFORMATION AND SERIAL NUMBER is located on the nameplate label on the rear cover of the oven.

NOTE: An electrical schematic is supplied with the oven. It is located in the back of the Display Panel in an envelope. Please return the schematic to the storage envelope for future use.

SERIAL NUMBER IDENTIFICATION is located on a serial number label attached underneath the lower right corner of the oven frame and on the rear cover.

CAUTION: It is extremely important that the model number be correctly identified. Electrical wiring and program changes have been made to the D3 oven. Information from earlier D models must not be applied to the D3 model. Use information from this manual only.

Wiring Information:

• European D3 models require a three phase WYE 5 wire power cord. This

oven must not be operated on three phase DELTA or single phase power.

• North American and Japanese three phase D3 ovens require a three phase DELTA 4 wire power cord. This oven must not be operated on three phase

WYE or single phase power.

• North American single phase D3 ovens require a 3 wire power cord. This oven must not be operated on three phase power.

1.2 INSTALLATION INSTRUCTIONS

1.2.1 Installation Requirements

The installation must be made in conjunction with an understanding of applicable CE, UL, cUL, NSF, and FDA requirements and appropriate local codes.

Before starting installation, the owner/installer should understand and agree upon: a) The installation policies of TurboChef Technologies Inc. b) The installation plan based on overview and preparation. c) The responsibility for testing, instruction of proper operation, use & care, and

preventative maintenance.

WARNING

a) DEATH, INJURY, AND EQUIPMENT DAMAGE could result from improper

installation of the TurboChef oven or installation of a unit which has been damaged during shipment or storage. Either of these conditions could void the

equipment warranty. b) DO NOT INSTALL a TurboChef oven suspected of damage. c) INSTALL the TurboChef oven according to the policies and procedures outlined

in this manual.

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1.2.2 Installation Precautions

(FRONT)

This equipment is designed and manufactured to comply with applicable CE, UL, cUL FDA, and FCC requirements. In addition, the unit is UL classified to NSF 4. All equipment is designed and certified for safe operation when installed in accordance with local and or national codes. Many local codes exist, and it is the responsibility of the owner and installer to comply with these codes.

In no event shall the manufacturer assume any liability for damages or injury resulting from installations which are not in compliance with the instructions and codes listed above. The manufacturer shall not assume liability for damage or injury resulting from improper installation of equipment including temporary or unstable work stations or counter tops.

The counter top or work surface must be able to support the weight of 650 pounds and should not exceed 30 inches in height.

There must be 1.75” (4.4cm) between the top of the unit and any shelf or surface.

The oven must be level front to back and side to side. The oven legs may be bolted to the counter top and must be bolted if it is placed on a rolling cart.

1.3 SPECIFICATIONS Physical characteristics:

Width: 31.5” (80cm) Height: 40.0” (101.6cm) Depth: 35.3” (89.6cm)

(Door handle closed)

37.0” (94.0 cm) (Door handle up)

Weight: 540 lb. (1190.7kg)

31.5”

(80cm)

(101.6cm)

35.3”

(89.6cm)

37”

(94cm)

40”

Electrical Characteristics:

North American European Japanese Model D3-A-5/6D4 D3-S-5/6S3 D3-E-5/6Y5 D3-J-5/6D4 Voltage: 208/240 V 208/240 V 400-415 V 200 V Frequency: 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz Connections*: 3Φ, 4 wire 1Φ, 3 wire 3NΦ, 5 wire 3Φ, 4 wire Current: 30/33 Amps 50 Amps 18 Amps 32 Amps Max Power Usage: Convection Oven: 7.0/9.0 kW 7.0/9.0 kW 9.0 kW 6.5 kW Microwave Oven: 4.0 kW 4.0 kW 4.0 kW 4.0 kW Microwave Freq.: 2450 MHz 2450 MHz 2450 MHz 2450 MHz Connector Type: NEMA 15-50P NEMA 6-50P IEC 309-32A NEMA 15-50P

* connections including ground

The oven is supplied with a 6’ power cord that includes a male connector. The outlet box, receptacle and wall plate are to be furnished by the installing contractor.

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1.4 OVEN ASSEMBLY

AIR FILTER

Air Filter and Frame

1. Remove the air filter and frame from their

shipping location on the back of the unit.

2. Slide the air filter frame into the brackets

on the bottom of oven below the cooking chamber. Secure the frame to the bottom front of the unit with a thumbscrew.

3. Slide the air filter into the frame.

Ceramic Cooking Platter

1. Carefully remove the packing

material from the ceramic Cooking Platter.

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2. Open the cooking chamber

door.

3. Place the cooking platter onto

the ring in the cook chamber door.

Waveguide Cap

1. Place the waveguide cap

centered on top of the screen basket.

Grease Pan

1. Slide the grease pan into the frame

on the bottom left side of the oven. Position the grease pan with the weep hole to the front of the oven.

GREASE

COLLECTION

PAN

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Cart (if applicable)

1. Lift the oven onto the cart. The holes in the top frame of the cart should line

up with the holes in the base supports of the oven.

2. Secure the oven to the cart as follows:

a) Place a washer, lock washer and nut on the bolt and tighten. DO NOT

over tighten or the cart’s tubing will become deformed.

b) Repeat for each leg

Additional Consumable Parts

These additional parts are to be used as spares. They should not be installed in the oven at this time.

Part Number Description Quantity of Spares (US only)

T100532 Grease Filter 3 T7000301 Ceramic Cooking Platter 2 + 1 (included with oven) T7000302 Waveguide Cap 2 + 1 (included with oven) T7001189 Chamber Basket 1

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SECTION 2 - OPERATING INSTRUCTIONS

2.1 GLOSSARY OF COMMON TERMS

Air - Percent of convection air flow during a cook event. Cook Temperature Set Point - The constant parameter, Cook Temperature Set

Point, is used by all Cook Settings.

Cook Chamber - Cavity in which the food products are cooked. Cook Cycle - Time of operation for a Cook Setting. Cook Setting Recipe - The food product cooking process. It consists of

duration, percentage of the hot air flow (AIR) required and microwave (TW) required.

Cook Mode - Execute the Cook setting instructions for selected food product. Cooking Product - The food product to be cooked in the oven. Cook Event - Segment of a cook cycle, up to 4 events can be used for each

cycle.

COOL-DOWN Mode - Turns OFF all oven components except the cooling fan. Display - Primary interface to relay messages to the operator. Duration - Time, in seconds, of a single cook event. EDIT Mode - Mode used to adjust the Cook Setting parameters. Keypad - Primary interface for the operator to control the oven. HEAT - Selects the cook temperature set point in EDIT mode. LED - Individual light indicators numbered 1 through 16 to show component

status. MAINTenance Mode - Mode used by authorized service personnel to check the

operation of oven components. Mode - The software environment which allows certain operations to occur.

There are several modes, NORMAL, COOK, SELF-TEST, EDIT, WARM UP, COOL DOWN and MAINTenance, in which the oven can operate.

NORMAL Operation Mode - Mode used to perform the "NORMAL" oven operations, such as, monitor the key pad for requests to cook or change mode, and maintain the oven at the Cook Temperature Set Point.

Parameter - A Cook Setting consists of two different kinds of parameters. Those which stay constant during a Cook Setting execution and those which can vary during different events of a Cook Setting.

Radio Frequency (RF) - The term used to describe the microwave emissions. Recipe - Cook Setting. The food product cooking plan. It will consist of up to four

Cook Events, each of which consists of duration, percentage usage of the hot air flow (AIR) required and microwave (TW) required.

RESUME - Continues Cook Cycle if interrupted such as by opening oven door. TW - Percent of Microwave used during a Cook Event. WARM-UP Mode - Brings the oven up to the Cook Temperature Set Point. SELF-TEST Mode - Self checks all critical components (magnetrons, heat

exchanger and blower are operational.

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2.2 BASIC OPERATING INSTRUCTIONS

2.2.1 Power On

The power switch is on the right side, lower front when your are facing the oven. Pull the power switch toward the top of the oven to energize.

2.2.2 Self Test/Warm Up

1. The machine will go through a self-check to verify that the critical components

(magnetrons, heat exchanger and blower) are operational. (If the oven

displays the message “Cooling Down”, Depress the “Warm Up” key to start.)

CAUTION: Self Test results are unpredictable if the oven door or filter door are not closed prior to or opened during the self test.

2. If any of the critical components are malfunctioning, the machine will stop at

the end of the test displaying a message identifying the faulty component. Refer to Troubleshooting Section for message definition. To continue press Stop.

3. When the self-check is complete and satisfactory, the machine will start

warming up and display "WARMING UP, HX Temp …". The HX Temp is the temperature of the heat exchanger. When the HX temperature exceeds a value determined by the cook temperature set point, the blower begins circulating air and the display indicates “CC Temp/HX Temp” on the lower line. The CC Temp is the temperature in the oven cook chamber. When the CC temperature reaches the cook temperature set point, warm-up is complete. The Warm Up should take approximately 30 minutes (shorter if the machine has not cooled down completely).

4. When the oven is ready to cook, it will display:

Select Recipe Or Select Recipe

CC 480° HX 571° If in Diagnostic Mode Heat 480/571°

2.2.3 Running A Recipe/Cook Setting CAUTION: DO NOT operate the oven without food or a suitable microwave

load in the cook chamber. This may damage the oven. CAUTION: DO NOT operate the oven with metal in the cook chamber. This

will damage the oven.

1. Open cooking chamber door by pulling the handle up, then pull the handle

outward until the door opens.

2. Place the food product in the appropriate position on the cooking platter.

3. Close cooking chamber door by pushing forward on the handle until the door

shuts, then push the handle down to latch into place.

4. Press the desired food (group) Cook Setting button.

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5. Press a button numbered 1 to 6 (subgroup) for food quantity or special food

definition. The display indicates the food group/subgroup name and cook time seconds (counting down).

6. W hen the cooking cycle is complete, the oven will beep and the display will

indicate "PLEASE REMOVE FOOD FROM OVEN". Remove the food product from the oven.

Note: Food will continue to cook with radiant and convection

energy when left in the oven due to the high cook chamber temperature.

7. The cook cycle is now ready to begin again.

Notes:

• If for any reason you want to stop the cooking cycle, press the “STOP” button

at any time. The user may close the door and press "RESUME" for the Cook Setting to continue.

• If the oven door or filter door is opened during a cook cycle, the oven will

automatically stop the current Cook Setting. The user may close the door and press “RESUME” for the Cook Setting to continue.

• If the “DARKER” key is depressed, 25% of the last cooking event is added as

additional cook time.

• Protection against exposure to microwave energy: Safety interlocks in the

oven doors prevent or terminate microwave operation when either the oven door or filter door is open.

2.2.4 Power Off

The power switch is on the lower right side, near the front when facing the oven. Push the power switch toward the bottom of the machine to de-energize.

2.3 OTHER OVEN OPERATIONS

2.3.1 Cool Down

An alternative to turning the power switch OFF when cooking is finished for the day is the "COOL DOWN" mode. This mode turns off all the major components but still allows the cooling fan to operate to keep the internal temperatures of the oven electrical parts down while the oven is cooling. To select "COOL DOWN" press the "COOL DOWN" button followed by the "ENTER" button. Opening the oven door will shorten the cool down time.

2.3.2 Warm Up

To remove the oven from "COOL DOWN" and return to the ready to cook state, press the "WARM UP" button. Make sure the oven and filter doors are securely closed. Remember, the oven may take up to 30 minutes to warm up.

2.3.3 Stop Key The "STOP" key can be utilized to stop the Cook Setting at any point in the cook cycle. The Cook Setting may be continued by pressing the "RESUME" key. The "STOP" key is also used to exit other modes such as "EDIT" or "MAINTENANCE".

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2.3.4 Darker Key

The "DARKER" key may be used to cook the food an additional 25% of the last cooking event. This may be useful to brown the food product or make the product well done.

2.3.5 Resume Key

The "RESUME" key allows a Cook Setting which was interrupted by the "STOP" key or opening the oven door to continue.

2.3.6 MAINTenance, Edit, and Heat Keys

Described in the section on Developing Cook Settings and Programming.

2.3.7 Catalytic Converter

The catalytic converter, T7001197, is installed in the return air duct downstream of the grease filter assembly. The installation of the catalytic converter requires a catalytic converter support frame, part # T7001195, to properly position it in the air path. The above parts may be ordered in kit form, # T7001200.

Operation and Indication of Problems

Due to the nature of most foods and the physics governing the operation of the TurboChef Oven, grease buildup downstream of the cooking chamber is inevitable. Strict cleaning regiments can solve a majority of the problems, however, recirculation of undiluted grease saturated air that is the main cause of downstream grease accumulation and any associated residual flavors.

The airborne grease will tend to collect and bake onto the oven surface downstream of the cooking chamber. This grease, due to the high operating temperatures of the oven, will start to rapidly decompose into derivative organic compounds.

These decompositional derivatives generally have positive and negative effects on cooking; the shorter chain derivatives add favorable flavor characteristics to the food, while the higher order carbon chains lend unpleasant flavor characteristics, such as bitter tarry tastes.

The installation of the catalytic converter greatly effects the grease handling and any residual flavors which might build up over time. A properly operating catalytic converter causes the conversion of airborne grease into water, carbon dioxide and small amounts of nitrogen and oxygen. The catalytic converter acts as a combustion chamber for the airborne grease. The catalysts present on the filter lowers the ignition temperature of the airborne grease from approximately 7000F to 450-5500F, allowing combustion to occur. The operating temperature of the oven directly determines the percentage of airborne grease conversion. A single pass of the air stream yields a 20-30% improvement in air quality.

A problem with the catalytic converter is indicated by a decrease in the effectiveness of browning (caused by a reduction in airflow) or by flavor transfer from one food group to another. Your operating parameters (daily use and oven run time) determines inspection/cleaning frequency. See cleaning instructions for procedure.

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2.4 DEVELOPING COOK SETTINGS AND PROGRAMMING

2.4.1 How to Develop your Cook Settings

Cooking with a TurboChef oven is different and exciting! It delivers hot food faster, at a higher quality than other ovens available today.

TurboChef uses both hot air and microwave energy to cook food. If you have experience with either a convection oven or microwave oven you will see similarities and significant differences. The key to creating good cook settings for your food is to understand the following rules:

1. TurboChef uses a moving shroud of hot air to surround the food. This locks in

the food’s moisture.

2. The hot air provides most of the heating and browning of foods. The higher

the air velocity, the faster heat energy is transferred to food.

3. The microwave provides heat to the center of the food. Don’t try to do all the

cooking with microwave!

4. The weight of food determines the total time required to cook. The more

weight, the longer the time required. (Most medium thick crust pizzas cook in about 100 seconds.)

5. Thick and dense foods may need to be flipped half way through the cooking

cycle.

6. Microwave works best in the early stages of cooking, then use hot air to finish

the cooking.

7. Color develops mostly at the end of the cooking cycle. Higher velocity air in

the later stages of cooking will strongly control the food’s color.

Don’t be afraid to experiment! Write down your current cook settings and then start testing. You can always go back to the old cook settings in a few seconds. Enjoy the power and flexibility of your TurboChef System.

2.4.2 Reviewing Existing Cook Settings

1. Press the EDIT key, key in the Access Number (PIN) and press ENTER.

2. Press the Recipe GROUP key you wish to review and observe the group

name.

3. Press ENTER.

4. Press a SUBGROUP key, key 1 through key 6, and the subgroup name

appears to the right of the GROUP name.

5. Press ENTER and observe the Duration in seconds, the percentage of hot air

flow (Air), and the percentage of microwave (TW) for the first event of the cook cycle.

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6. Press ENTER and the second event parameters are displayed. The Cook

Setting ends when an event with zero time duration is encountered or all four events are used. If the first event of a Cook Setting has a duration of zero time, no Cook Setting is defined.

7. Press EDIT to return to step 2.

8. Press HEAT and observe the cook temperature set point. The cook

temperature set point applies to all GROUP/SUBGROUP cook settings.

9. Press STOP to return to normal operation.

2.4.3 E diting Cook Settings

1. Press the EDIT key, enter Access Number (PIN) and Press ENTER.

2. Press the Recipe GROUP name key of the Cook Setting you wish to edit.

3. Edit the food group name using the left/right arrow keys to position the

blinking cursor. Nine characters are available for the food group name. Repeat pressing an alpha/numeric key until the needed letter or number appears. The up/down arrow keys select upper case or lower case letters. Use the right arrow key to advance to the next character position. The SP key replaces a character with a space and advances to the next character position. Press ENTER when the new name is complete. Note: When the existing information is correct, simply press ENTER to store the information and move to the next display.

4. Press a SUBGROUP key number, 1 through 6, to indicate quantity or special

food definition.

5. As described in Step 3, likewise edit the subgroup name. Press ENTER.

6. Observe the three parameters for cook event 1. The blinking cursor indicates

the Event Duration is selected for editing. Use the left/right arrow keys to select the other parameters, blower power (AIR) or microwave power (TW).

7. Using the numeric section of the keypad, key in the correct time or

percentage and press ENTER. The blinking cursor will advance to the next parameter. Note: You must press ENTER to replace previous settings with new settings. Be careful not to change a setting and move the blinking cursor without pressing ENTER to save the setting.

8. If a setting is not changed and ENTER is pressed, the display will advance to

the next event. Use the up/down arrow keys to select any of the 4 events to edit or review.

9. W hen 4 events are not required for the cook setting, set the duration of the

first unused event to 0. Note: If the duration of event #1 is set to 0, the

GROUP/SUBGROUP selection has no cook setting and displays “NO RECIPE ENTERED” when selected.

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10. Valid event duration time is 1 to 255 seconds. However, the combined

duration of all events, i.e., the total Cook Setting cook time, should not exceed 999 seconds. Valid blower power (AIR) is 20% to 100% in 5% increments. Valid microwave power (TW) is 0%, 50%, or 100%.

11. Anytime you wish to select a different Cook Setting to edit, press EDIT and

return to step 2.

12. To review or edit the Cook Temperature Set Point, press HEAT. Enter a new

temperature from the numeric keys and press ENTER. Note: The same Cook Temperature Set Point applies to all GROUP/SUBGROUP Cook Settings.

13. When editing is complete, press STOP to return to normal cook mode.

2.3.4 Maintenance Operations

The MAINTenance mode allows you to manually control the various hardware components of the oven and display operational information

Press the MAINTenance key, enter access number (PIN) and press ENTER.

1. VER key alternately displays the version of the oven operating system

(hardware and software) and the oven recipe version if loaded by the ChefComm utility.

2. HTR key turns the Heat Exchanger On and Off. If the heat exchanger is over

the maximum allowed temperature (Approximately 700 degrees F), the heaters can not be turned on. An over temperature thermostat also prevents heater runaway. LED 11 indicates heaters are selected and LED 16 indicates current is flowing to the heaters. This key also resets the COOK TEMP TOO LOW message.

CAUTION: DO NOT leave the heaters on for long periods, as the oven will rapidly heat to maximum allowed temperature (Approximately 720qF(382qC).

3. %BLO key increases the convection airflow in 10% increments. Repeat

pressing key to select new air speeds. When the airflow is 100%, the next key press resets airflow to 0%. If the blower is Off (LED 7 is no t illuminated) the %BLO key is ignored.

4. BLR key turns the convection air blower On or Off. LED 7 indicates the status

of the blower motor speed controller. The blower will return to controlled operation when MAINTenance is exited. This key also resets the BMSC DEFECTIVE message.

Page 17 of 87

5. M12 key energizes both magnetron 1 and 2 when the key is held depressed.

There will be a 3 second delay while magnetron filaments heat up initially. The filaments will stay on for 3 minutes after the end of the last time the magnetrons were energized. To conserve power, the Heat Exchanger is turned OFF when the key is pressed. The display provides an un-calibrated indication of the power level in the microwave waveguide cavity. The power reading varies with the motion of the microwave stirrer blade. The magnetron turns OFF when the key is released. This key also resets the Mag RF FLUC LO, Mag CURRENT LOW and Mag THERMO SW messages.

CAUTION: DO NOT hold the key more than 5 seconds without a cooking product or suitable microwave load in the oven.

6. PIN key allows for entry of an alternate personal identification number for

accessing EDIT and MAINTenance modes. If ChefComm is implemented, the

PIN will also reset the “New Settings” message. Enter from 1 to 4 n umbers or letters and press ENTER. Be sure to keep a record of the PIN you choose.

7. CCC key displays the Cook Cycle Count. Press key a second time and a

message prompts to press SP/CLR to reset the count to zero.

8. EC key displays the temperature of the electronics compartment. If the EC

thermocouple is open or missing, “EC THERMO OPEN” is displayed. The EC temperature should not exceed 140°F(60°C) under normal conditions.

9. WARM key causes the MAINTenance mode to be exited and the WARM-UP

mode to be selected without executing SELF-TEST.

10. DIAG key performs two functions. The first press displays the heat exchanger

rate of temperature rise, degrees per minute. This number is used by the oven operating system to replace heat lost during cooking and maintain cook temperature when the oven is idle. If MAINTenance mode is exited after the first press, a diagnostic display is presented during cook and heat maintenance cycles. The display shows all parameters, RF power, percent airflow, CC and HX temperature, and the accumulated and target BTU during cooking for each event.

The second press indicates if the temperature rise was measured or

defaulted to the last known measurement. The measurement is taken during oven warm up when the initial cook chamber temperature is less than one half the cook temperature set point. To keep the normal display, exit MAINTenance after the key press showing the measured or default message.

11. IAF key selects the amount of air flow when the oven is idle (not Cooking).

When IAF is first pressed, the current Idle Air Flow is displayed. The IAF range is 0% to 50% in 5% increments. Repeat pressing the IAF key to select a new air flow. Then press ENTER to set the new IAF.

Page 18 of 87

12. SN key is used to enter the oven serial number. The first time SN is pressed

the current serial number is displayed. A second press clears the serial number field and awaits entry of a new number. Up to 14 alpha/numeric characters may be entered. Repeat pressing an alpha/numeric key until the needed letter or number appears. Use the right arrow key to advance to the next character position. The left arrow key moves the cursor to the left to permit changing a previously entered character. The SP key replaces a character with a space and advances to the next character position. The serial number is updated when ENTER is pressed.

13. FF key is used to display and reset oven fault flag counters. Repeat pressing

the FF key to display the 6 faults, BMSC Status, Low Cook Temperature, Low Mag Current, Low RF Fluctuation, Mag Thermo Switch, and EC Over Temperature. The counters increment from 0 to 255 and roll over to 0. To reset a counter, repeat pressing FF to select the fault and press SP/CLR.

14. F/C key is used to select Fahrenheit (ºF) or Celsius (ºC) temperature scale for

the display. If Fahrenheit temperature is currently displayed, pressing F/C will change the display to Celsius and visa versa.

15. MS key is used for modem selection when the oven is connected via

telephone to a remote ChefComm facility. Refer to document T700155 for ChefComm operation.

Press the MAINTenance or STOP key to return to normal cooking operation. The magnetrons and heaters are turned OFF, the blower controller is returned to the ON or operational state and the air flow is set to the IAF setting bef ore returning to normal cooking operation.

2.4.5 Replacing Keypad Menu Label Strips

1. Remove menu label strips by inserting a small pointed object, such as a

wooden toothpick, under the keypad film and pull out until the strip appears and can be removed by hand. Use caution in order to avoid damaging keys, cutting the keypad film or scratching the stainless steel panel.

2. Install a new menu strip by holding the keypad slot open with a small pointed

object and sliding the new menu strip into place. Again, use caution to avoid cutting the keypad film or scratching the stainless steel panel.

Page 19 of 87

2.5 CONTROL PANEL LAYOUT

/#+06

2.5.1 Keypad Layout

NOTE: Subscripts used in MAINTenance and EDIT modes only.

Ver

Htr

%Blr

Blr

2.5.2 Status LED Indicator Layout

Cook Door Primary 1 Cook Door Secondary 2 Cook Door Monitor 3 Filter Door Primary 4 Filter Door Secondary 5

M12

' (

)

CCC



IAF ABC1



JKL4

/+%41

••



SN DEF2



FF MNO5

/+%41 #+4

°C/°F

9 10 11 Heat Exchanger 12 Magnetron 1 Temperature OK 13 Magnetron 2 Temperature OK



MS GH13



PQR6

#+4

'&+6

*'#6

%11.

&190

5612

9#4/

-'4

4'57/'

3DQHO

Filter Door Monitor 6 Blower Running 7

When light is on, item is active.

••

14 Magnetron 1 On 15 Magnetron 2 On 16 Heat On

Page 20 of 87

SECTION 3 – CLEANING AND SELF TEST

3.1 BASIC CLEANING PROCEDURES - CARE AND CLEANING Carbon and grease build-up will adversely affect the cooking performance

and life expectancy of certain components of the TurboChef oven. It is the

operator’s responsibility to properly maintain this unit. Failure to maintain this unit in a clean condition will void the warranty.

WARNING: Never use a NaOH (Lye) based chemical to clean the Turbochef oven. Use of NaOH (Lye) based chemicals can damage critical components and will void the warranty.

3.1.1 SUPPLIES NEEDED

•

Non-Lye Non-Caustic Oven Cleaner

•

Non-Lye Non-Caustic Degreaser

•

All Purpose Cleaner

•

Oven Coating (optional) To more easily maintain a clean oven (especially back wall of cooking chamber), grease shield oven coatings may be applied, after oven has been cleaned

NOTE: For a specific listing of non-caustic, non-lye cleaning products, call your local Authorized Service Provider.

3.1.2 CLEANING EQUIPMENT

•

Nylon 3x5 green scrub pads

•

Dry, clean towels

•

Sheet pan

•

Firm bristle brush (6-8 inch handle with 2x2x1 bristles)

•

Bottle brush – small (3 inch test tube diameter),

•

Protective rubber gloves,

optional

Page 21 of 87

3.1.3 DO’S AND DON’TS OF CLEANING DO – Keep the oven clean. Daily cleaning is recommended.

DO – Be careful when cleaning the oven. Surfaces stay hot for a long time. DO – Switch the oven off at the circuit breaker before cleaning. DO – Thoroughly wipe all surfaces that come in contact with oven cleaner with a

damp sponge or cloth.

DO – Remember oven door is heavy. Use two people to remove and replace. DO – Change the grease filter if it is holed or clogged. DO – Put grease filter back in the correct way. DO – Clean bottom air filter weekly. DO – Clean ceramic platter with a non Lye based cleaner then rinse off and dry. DO – Clean ceramic wave guide cap with a non Lye based cleaner then rinse off

and dry.

DO NOT – Place hot ceramics on cold surfaces. DO NOT – Allow ceramics to soak in any liquid for any period of time. DO NOT – Remove any panels from the oven (except lower access panel). DO NOT – Allow water to be forced up into the air holes in the roof of oven. DO NOT – Allow build up of grease or carbon on any surface in the oven. DO NOT – Spray LYE BASED oven cleaners into the oven. DO NOT – Use metal objects to clean the oven. (Other than scraper used for

hard to remove carbon and debris in weekly / monthly cleaning).

DO NOT – Spray non-caustic oven cleaners, degreasers, and grease shield

products or any other liquid onto the wave guide seal.

DO NOT – Scrub the wave guide seal. DO NOT – Throw the grease filter frame assembly away. DO NOT – Spray grease shield products on the catalytic converter DO NOT – Bang catalytic converter on a hard surface to clean

Page 22 of 87

3.1.4 MINIMUM DAILY CLEANING PROCEDURE

CAUTION: Before cleaning turn the unit off at the unit’s power switch, then turn off main power supply breakers! (Power switch is located on the right side panel at lower front corner)

STEP 1: Preparing the oven for cleaning

1. Turn off power at the switch. Disconnect the power supply.

2. Open the oven door.

3. Allow the oven to cool for a minimum of 45-60 minutes to ensure safe

handling.

STEP 2: Cook Chamber parts  Carefully remove the cooking platter, chamber basket and ceramic

waveguide cap. Set aside.

CAUTION: Handle the Ceramic Cook Platter and Wave-guide Cap carefully to avoid breakage.

CERAMIC WAVEGUIDE CAP

COOK CHAMBER DOOR ASSEMBLY

COOKING PLATTER

CHAMBER BASKET

(COOK CHAMBER)

Page 23 of 87

STEP 3: Cleaning

1. Take the dirty parts to a well ventilated area for cleaning.

2. Spray all three pieces generously with non-lye non-caustic oven cleaner or

non-lye non-caustic degreaser and set aside (Allow the cleaner to penetrate).

CAUTION: DO NOT soak Ceramic Cook Platter or Waveguide Cap in water.

NOTE: Use a second ceramic cooking platter, wave-guide cap, and chamber basket in daily rotation (ovens are shipped with spare parts) to eliminate the wait time for the oven cleaner to work. Spray the pieces coming out of the oven and set aside until the next day. Clean, rinse, and dry the set from the previous day, (or use new), install into the oven, and proceed to warm up.

3. Thoroughly scrub inside of oven door, front ledge, top, side and back walls of

cook chamber using non-caustic degreaser (non-lye based), and a scrub pad (green mesh).

4. Clean ceramic cooking platter, wave guide cap, and chamber basket using

recommended brushes and scrub pads. Rinse to remove all cleaner and debris. Only the chamber basket may be placed in a dishwasher.

5. Check grease collection pan (located on bottom of oven) for grease and

debris. Empty, clean and reinstall.

6. Rinse parts thoroughly; and reinstall clean parts into the oven.

7. Turn on oven and observe the oven’s self-test.

GREASE COLLECTION PAN

(GREASE CLEANING)

Page 24 of 87

3.1.5 WEEKLY/MONTHLY CLEANING PROCEDURE

CAUTION: Before cleaning turn the unit off at the unit’s power switch, then turn off main power supply breakers! (Power switch is located on the right side panel at lower front corner)

We recommend completing the following procedure once a week. Certain oven applications will require more or less frequent cleaning.

Oven cleaners require up to four hours to effectively clean the cook and filter cavities. We recommend completing steps 1-4 after closing and finishing the cleaning procedure the following morning.

STEP 1: Preparing the oven for cleaning

1. Turn off power at the switch. Disconnect the power supply.

2. Open the oven door. Allow the oven to cool for a minimum of 45-60 minutes

to ensure safe handling.

STEP 2: Cook Chamber parts

1. Carefully remove the cooking platter, chamber basket and ceramic wave-

guide cap.

 Spray all three pieces generously with non-lye non-caustic oven cleaner or

non-lye non-caustic degreaser. (Allow the cleaner to penetrate)

 Place the clean wave-guide cap into the oven. This will protect the wave-

guide seal while the cook chamber is cleaned.

CAUTION: Handle the Ceramic Cook Platter and Wave-guide Cap carefully to avoid breakage. DO NOT soak Ceramic Cook Platter or Waveguide Cap in water.

CERAMIC WAVEGUIDE CAP

COOKING PLATTER

CHAMBER BASKET

COOK CHAMBER DOOR ASSEMBLY

(COOK CHAMBER)

Page 25 of 87

STEP 3: Grease Filter

PANEL

(GREASE FILTER)

1. Remove the lower access panel.

2. Remove the filter door. Spray the filter door with a non-caustic non-lye oven

cleaner.

3. Remove the filter assembly from the housing.

4. Tap the filter assembly gently, on the side of the trash can to remove loose

carbon particles. You may run the filter assembly through the dishwasher if necessary. Set all of the filter parts aside.

CATALYTIC CONVERTER

SUPPORT FRAME

FILTER DOOR/GREASE FILTER

BOTTOM ACCE SS

ASSEMBLY

STEP 4: Cleaning the Cook Chamber

1. Spray non-caustic non-lye oven cleaner evenly and thoroughly into cooking

chamber and filter chamber. Be sure to cover inside walls, top, sides, etc. of cooking chamber.

CAUTION: The wave-guide seal (located under ceramic wave-guide cap) should be protected by the wave-guide cap during oven cleaning. Make sure cap is in place while spraying cleaners into cooking chamber and during the cleaning process.

2. Remove cook chamber door by releasing the latches at the rear of each side.

The door should be thoroughly cleaned with a non-lye oven cleaner.

CAUTION: Oven door is extremely heavy, use two people.

Page 26 of 87

In the Morning

STEP 5: Cleaning the oven

1. Using damp cloth or green scrubby, thoroughly scrub the side and back walls,

as well as the top of the oven chamber. Use stiff blade scraper if needed (do not use scraper on the wave-guide plug seal).

2. Once oven chamber has been cleaned, push debris through the opening

down into the filter chamber.

3. Wipe down interior of oven with damp cloth.

CAUTION: Remove all chemical residue to ensure food safety.

4. Remove ceramic wave-guide cap and wipe clean.

5. Clean filter chamber and pull debris into crumb tray. Empty crumb tray and

rinse with a damp cloth and wipe dry.

6. Use brush to loosen debris, or run through dish machine (do not soak). Allow

parts adequate time to dry.

7. Check grease collection pan (located on bottom of oven, below filter door)

and empty. Clean and replace.

STEP 6: Air Filter and Ventilation

1. Check bottom air filter (located next to grease collection pan on bottom of

oven). If dirty, soak in water with mild detergent.

2. Check circular vent located above bottom screen and clean vent screen as

needed.

3. Replace bottom air filter.

GREASE

COLLECTION

PAN

AIR FILTER

(FILTER CLEANING)

Page 27 of 87

STEP 7: Reassemble oven

1. Replace door back into oven.

2. Caref ully replace filter door and lower access panel (oven will not start up if

filter door is not properly in place).

3. Replace cleaned ceramic cooking platter, chamber basket, wave-guide cap

and bottom air filter into oven.

4. Wipe down exterior of oven with a damp cloth and all-purpose cleaner.

Stainless steel polish may be used on the exterior only.

5. Reconnect oven at power supply.

6. Turn on oven at breaker switch.

7. Power on oven and observe Self-Test.

3.1.7 PERIODIC SIX-MONTH SCHEDULED CLEANING PROCEDURES

This procedure is recommended to lengthen the life of your TurboChef oven.

STEP 1: Cook Chamber Door

1. Release the latches on the rear slide rails of the cook chamber door

assembly.

2. Remove the cook chamber door.

CAUTION: Door assembly is extremely heavy (approximately 39.5 lbs.) and awkwardly balanced. It is recommended that two people remove and re-install the door assembly.

LATCH

RELEASE

(LTCHREL)

Page 28 of 87

STEP 2: Slide Bearing Assemblies

1. Remove the socket head screws holding the four slide roller bearing

assemblies to the cook chamber side walls.

2. Clean the assemblies with hot water mild detergent.

3. Water rinse and dry.

4. Clean the oven side walls with hot water mild detergent. Take caution to

avoid excessive wetting or damage to the waveguide plug.

5. Water rinse and dry.

6. Reinstall four bearing assemblies.

WARNING: Be sure to reinstall the door stop brackets on the rear assemblies for proper operation.

DOOR STOP

BRACKETS

(SLIDE)

Page 29 of 87

STEP 3: Rear Access Panel

1. REMOVE the rear access panel from the oven to expose the rear slide

channel end caps.

REAR

ACCESS PANE

(BACKPNL)

STEP 4: Rear Slide Channel End Caps

1. REMOVE four screws holding each rear slide channel end cap

2. CLEAN inside the rails with hot water and mild detergent using a wire brush.

3. WATER rinse and dry.

4. REINSTALL the end caps.

REAR SLIDE CHANNEL

END CAPS

WITH HARDWARE

(CHCAPS)

Page 30 of 87

CAUTION: DO NOT operate without end caps in place.

5. REINSTALL rear access panel.

Page 31 of 87

STEP 5: Catalytic Converter

CAUTION: To prevent burns, only service the catalytic converter when the oven is cool.

1. Remove the lower access panel by rotating installed handles up to expose

the grease filter area.

2. REMOVE the filter door and grease filter assembly by lifting up on the filter

door handle and removing the grease filter assembly.

3. REACH into the rear of the grease filter area and push the catalytic converter

up into the return airduct. Pull the support frame out while the catalytic converter is raised. Remove the catalytic converter from the rear of the grease filter area. CLEAN the catalytic converter support frame if necessary.

4. Inspect the catalytic converter for cleanliness. Look mainly for any blockages

caused by gummy organic particles. If there are no blockages, a simple rinse with distilled water is sufficient and the catalytic converter can be reinstalled.

CAUTION: At no time should the catalytic converter be exposed to any oven cleaners or degreasers, unless otherwise specified.

If there are blockages use the following procedure to dislodge them: a) Shake catalytic converter to dislodge any large particles trapped in the

filter cells.

b) Mix a 6.5:1 solution of grease-off oven cleaner concentrate (6.5 parts) and

distilled water (1 part). Soak the catalytic converter in the solution for 30 minutes to 1 hour.

c) Soak/rinse the catalytic converter using distilled water for 10 minutes. This

process may be repeated if necessary.

CAUTION: Do not pound filter on counter tops or tap with any objects. DO NOT use any type of abrasive materials to clean Catalytic converter. CAUTION: Solutions containing phosphates, sodium, or other surfactants

must be avoided. Also it is very important, due to varying water qualities, that the user only use distilled water during cleaning of this unit.

5. Reinstall the catalytic converter. Be certain that the catalytic converter and

support frame are properly positioned in the return air duct. Reinstall the grease filter, filter door and lower access panel. Allow the oven to undergo a warm-up cycle to dry the catalytic converter.

Page 32 of 87

Catalytic Converter

Support Frame

Grease Filter Assembly

Filter Door

Grease Filter Area

STEP 6: Reinstall Door

1. REINSTALL the cook chamber door assembly. CAUTION: Be sure the door rail catches are caught and door stops

operate correctly

(Cat Conv)

3.2 MAINTENANCE MODE TROUBLESHOOTING

Only authorized service personnel familiar with electrical repair and related personal service considerations should attempt the following diagnostics and repair.

Maintenance Mode Diagnostic Tests

Place the oven in MAINTenance mode for the following tests. (Press the MAINT key, enter the appropriate Access Code and press ENTER). Take the following readings and record the data:

1. Cooking chamber temperature recorded after oven is warmed up and

stabilized in Heat Maintenance Cycle. (CC °F) ___________ The cooking chamber temperature, after the oven has completed its warm up

cycle, should be within 20°F of Cook Point Setting (typically 540°F).

2. Heat exchanger temperature recorded after oven is warmed up and

stabilized. (HX °F) ___________

Page 33 of 87

If the IAF setting is 0%, the HX temperature should be approximately 60°F above the Cook Set Point temperature after the oven is properly warmed up. If the IAF is greater than 0%, the HX temperature will be much closer to the Cook Set Point temperature.

If the temperature is LOW, go to 5 (Heat Exchanger). If the temperature is HIGH, go to 3 (Blower).

3. Blower (press BLR). The blower condition changes when the BLR key is

pressed. LED 7 will turn on to indicate the blower is on. ______ON ______OFF

If the blower does not come on proceed with the following steps. After each step, press the BLR key and then STOP once the blower comes on.

a) Reset the blower motor drive by turning the oven off, wait 30 seconds

minimum, then turn the oven on.

b) Check AUX1 (AUX2) fuse(s). If a fuse is found to be open, replace with a

fuse identical in type and rating. For additional reference see the appropriate schematic for the oven mode.

c) Check the connectors to the printed circuit boards located in the electrical

control box behind the keypad panel to ensure proper mating.

4. Blower Speed (press %BLR key). With the blower in the On condition the

blower speed should increase in 10% increments up to 100%. ______YES ______NO

5. Heat Exchanger (press HTR key). LED’s 11 and 16 should come on when the

key is pressed. _____YES ______NO a) IF neither LED comes on, the heat exchanger may be over the maximum

temperature (700°F).

b) IF LED 16 does not come on, check HTR1 and HTR2 fuses and replace if

necessary with the same type and rating.

c) If the fuses are good, the over temperature thermostat, OT1, may by

tripped.

6. Mag1 and 2 (press M12 key). LEDs 14 and 15 should come on when the key

is pressed and held. ______ON ______OFF If LED 14 or 15 do not come on, verify status LEDs 1, 2, 3, 4, 5 and 6 are on

with the cook door and filter door closed. a) If status LEDs are all on, check and replace magnetron fuses as

required.

b) If status LED’s are not all on, determine which LED’s are not on and

check the appropriate interlock and monitor switches for proper contact and alignment.

Page 34 of 87

7. Magnetron Power Verification:

CAUTION: Use care in disposing of hot water.

Check the combined magnetron power by placing a shallow microwave safe dish with 1000ml or 33.8 oz of cold water (approximately 40°F) in the oven. Measure the initial water temperature. Using MAINTenance mode and M12 key, turn both magnetrons on for 60 seconds. Measure the final water temperature. The water temperature rise should be a minimum of 45°F (25°C).

3.3 SELF TEST AND ON-LINE ERROR MESSAGES

3.3.1 SELF TEST - Defective Messages

Refer to 3.3 Self Test Flow Chart to determine logic tests performed.

Note: When a “… Defective” Message is encountered, the operator may press any key to continue the self-test. The software will track this fault for future verification.

Displayed Message Go To

1. “BMSC DEFECTIVE” 4.3

2. “HX Heat Thermo OPEN” 4.7

3. “HX Heat °F RISE LOW” 4.7

4. “CC Heat Thermo OPEN” 4.7

5. “CC Heat °F RISE LOW” 4.7

6. “Mag 1/ (2) CURRENT LOW” 5.4

7. “Mag 1/(2) RF FLUC LOW” 5.4

8. “Mag 1/ (2) THERMO SW” 5.4

9. “Oven Door Open” 6.2

10. “Filter Door Open” 7.0

11. “Keypad DEFECTIVE” 8.3

Page 35 of 87

3.3.2 ON LINE (while cooking) - Diagnostic Messages

Refer to 3.4 On-Line Flow Chart to determine logic tests performed.

Note: Only “Cook Temp Too Low” and “BMSC DEFECTIVE” cause a cook cycle to terminate. Magnetron failures as well as cook temperature variances cause cook cycle time extensions (shortening) to compensate for lost (increased) available cooking energy. Each time another cook cycle is started, the faults are reset and retested.

Displayed Message Go To

1. “BMSC DEFECTlVE” 4.3

2. “COOK TEMP TOO LOW” 4.7

3. “EC Temp ___ °F” 8.2

4. “Mag CURRENT LOW” 5.4

5. “Mag RF FLUC LOW” 5.4

6. “Mag THERMO SW” 5.4

Page 36 of 87

3.4 SELF TEST FLOW CHART

Turn

on oven

power

1 sec later

Cool Down

state?

Filter Door

secure?

Yes

Oven Door

secure?

Yes

Energize MAG

Filaments

MAG 1

Over Temp

OK?

Yes

Energize

MAG 1 and 2

Yes

COOLING DOWN

Alarm and Display

FILTER DOOR OPEN

Alarm and Display

OVEN DOOR OPEN

MAG 1 THERMOSW

Display

Cool

Down

Display

After 3

sec is MAG 1

current

Yes

After 6

sec RF pwrd

stirrer

After

12 sec into

test

Was Test

MAG 1

Yes

Replace MAG 1

with MAG 2

Display

MAG 1 CURRENT LOW

Yes

Display

MAG 1 TEST OK

Yes

Display

MAG 1 RF FLUC LOW

Press any key

to continue

Go to

(Flow 1)

Page 37 of 87

(Flow 2)

Equals

240

Page 38 of 87

3.5 ON-LINE FLOW CHART

Blower ON

For Current

Event

TW ON

For Current

Event

Yes

TW = 50%

Yes

Are

Both MAGS

Drawing

Current

Either

Magnetron

Drawing

Current

Yes

P/O

COOK

After

5 sec Cook

With Blr On Is

Temp 85 Deg

Below Set

Point

Yes

Blower

Running

RF Delta

OK and NO

Prior Low

Fluc

Yes

13 Seconds

Into Event

Yes

Queue Message

"MAG RF FLUC LOW"

Keep MAGs on

(Do not pulse)

Stop Cook, Display

COOK TEMP TOO LOW

Stop Cook, Display

BMSC DEFECTIVE

NoYes

Reset Fault

MAG CURRENT LOW

Increment Fault Counter

COOK TEMP TOO LOW

Increment Fault Counter

BMSC DEFECTIVE

Increment Fault Counter

"MAG RF FLUC LOW"

Go to SELECT RECIPE

Yes

Already

Mag Current Lo

Thermo Sw Fault

Mag Thermo Sw

and NO Previous

Mag Thermo

Sw?

TW = 50%

Yes

Queue Message

MAG THERMO SW

Queue Message

MAG CURRENT LOW

Have

5 seconds

Yes

past?

Increment Fault Counter

MAG THERMO SW

Increment Fault Counter

MAG CURRENT LOW

Are

Yes

MAGS

on?

Turn off

Turn on

MAGS

CONTINUE

COOK

(Flow 3)

Page 39 of 87

SECTION 4 - CONVECTION SYSTEM

4.1 BLOWER MOTOR ASSEMBLY

1. BLOWER WHEEL TIPS FACE AWAY FROM MOTOR (AS SHOWN)

2. LABEL ORIENTATION IS TO BE LEFT TO RIGHT AS FACING MOTOR. LOCATE IN AREA SHOWN, KEEPING LEFT EDGE PARALLEL TO MOTOR FLANGE.

4 PL

(0.150 .020)+

2 134 PL 14 21 222 PL

DETA IL A

SCALE: 2/1

26 2 PL 27

2 PL 2 PL

(4.00)

10 4 PL

SEE DETAIL A

7 4 PL

BLOWER MOTOR ASSEMBLY - DWG 700-0310

ITEM PART NO. DESCRIPTION

1 T7000304 MOTOR MOUNTING PLATE 2 T7000306-2 HUB, FAN, SMALL

- T0048 BLADE RING 3 T7000307-1 BLADE, FAN 4 T7000308 BLOWER RING 5 T7000311 BLOWER CAP 6 T102708 HEAT SLINGER 7 T7000314 STANDOFF, MOTOR 8 T7000284 SHIM, SHAFT SEAL

- T0052 MOTOR MOUNT FANGE, NUTS AND BOLTS 9 T102732 MOTOR, FLANGE MOUNT, 1 HP, 7050 RPM

10 T101391 1/4-20 X .75 LG. SCREW, PFH, SS 11 T101830 3/8-16 X .75 LG. SCREW, SOCKET HD. CAP, SS 12 T101751 1/4-20 X .75 LG. SCREW, SOCKET HD. CAP, SS 13 T101746 8-32 X .38 LG. SCREW, SOCKET HD BUTTON, SS 14 T102320 # 8 WASHER, LOCK, INTERNAL TOOTH, SS 15 T100791 #242 LOCTITE THREADLOCKER 16 T7001154 LABEL, EXPOSED FAN DANGER 17 T102410 # 3/8 WASHER, LOCK, SPLIT, SS 19 T102400 # 1/4 WASHER, LOCK, SPLIT, SS 21 T100730 KEY, WOODRUFF, SS 22 T101715 8-32 X .25 LG. SET SCREW, SOCKET HD, SS 23 T7001177 GRAPHITE BLOCK, BEARING SEAL 24 T101733 SPRING, COMPRESSION, SS 25 T7001179 CLAMP, BEARING SPRING 26 T101005 10-32 NUT, LOCK, CRES 27 T102140 # 10 FLAT WASHER 28 T102350 #10 SPLIT LOCK

17 4 PL 11

1 12 4 PL 19

4 PL

(Blower Motor)

Page 40 of 87

4.2 BLOWER MOTOR CONTROLLER TESTS

The blower motor operates during the normal idle operation (the speed is set by IAF in Maintenance mode for stabilization of the oven temperatures), while in the cooking mode at the desired speed, and during the MAINTenance mode. The MAINTenance mode allows the service technician to manually operate the blower on and off and to change the speed.

Note: The Blower Shaft rotates in the clockwise direction when viewed from front of oven.

4.3 BLOWER DEFECTIVE MESSAGES

The TurboChef oven will display a defective (fail) message, “BMSC DEFECTIVE”, if the RUN status from the Blower Motor Speed Controller is absent during self-test or while cooking.

In either case, they can be caused by the following problems:

SELF TEST WHILE

COOKING

BMSC DEFECTIVE

CAUSE CORRECTIVE ACTION

Blower Motor Speed Controller not returning the

“Running” status. (See indicator LED 7)

1. Check BMSC Temperature. If below 0°C, let controller warm up and try again

2. Check Blower Fuses (See 8.0)

3. Check Air Filter for cleanliness.

4. Check Cooling Fan operation.

5. Check for proper operation of interlock/monitor switches.

6. Check fault message on BMSC. (See 4.4.2 or Reliance Electric Manual.)

7. Check BMSC Settings. (See

4.5.2.)

8. Check all connections in the blower circuit (Ribbon cables, all blue wire signal circuits).

9. Replace BMSC. (See 8.0)

10. Replace I/O CCA. (See 8.0.)

11. Replace Blower Motor Assembly. (See 4.1.)

12. Replace Controller CCA. (See

8.3.)

Page 41 of 87

4.4 BLOWER MOTOR CONTROLLER DEFECTIVE MESSAGES

4.4.1 Fault Codes

The SP500 controller requires only minor troubleshooting. If a fault occurs, the controller displays fault (ERR) codes to assist in troubleshooting. If a fault condition occurs while the drive is running, (LED 7 on), the drive coasts to rest and a 2-digit fault code is flashed on the display.

The fault code is also entered into the error log. The error log is designated as

“ERR” on the display.

4.4.2 How to Access and Read the Error Log

Multiple fault codes are entered into the error log in sequential order. The first error to occur flashes on the display and two more errors may be logged into the error log. (The error log must be accessed to see them). After three faults have occurred, no more subsequent faults will be entered into the error log.

The faults entered into the error log are numbered sequentially. If first an overcurrent fault were to occur, it would be in the error log as "1=OC". If next a thermal overload fault were to occur (and the first error was not yet cleared), it would be in the error log as "2-OL", and so on.

The last fault to occur will appear first when accessing the error log. For example, if the last fault was a low bus fault, and the error log has 3 entries, then the error log would display "3-LU" when the error log is first accessed.

Faults are retentive to the error log if a power loss occurs. The entire error log can be cleared by pressing the STOP/RESET button.

To access the error log:

1. Press the MODE/ENTER key until the Program LED lights.

2. Press the down arrow key until “ERR” is displayed. The error log precedes parameter F-00 and follows F-49.

RPM RUN % Load Program Volts Forward Remote Reverse

Mode Enter

START

Mode Enter

START

Forward Reverse

STOP

RESET

(Error 1)

Forward Reverse

STOP

RESET

(Error 2)

Page 42 of 87

3. Press the MODE/ENTER key to access the error log.

4. Press the up arrow key to move through the error codes.

5. Press the STOP/RESET key to clear the error log. Refer to 4.4.3.

6. The display returns to the active monitor display.

RPM RUN % Load Program Volts Forward Remote Reverse

Mode Enter

START

Mode Enter

START

Mode Enter

START

Forward Reverse

STOP

RESET

(Error 3)

Forward Reverse

STOP

RESET

(Error 4)

Forward Reverse

STOP

RESET

4.4.3 Messages in Error Log

OH: Thermostat / Drive Overload

Cause Action The internal thermostat has caused a trip that indicates

excessive temperatures in the controller.

1. The ambient temperature of the controller is exceeded.

Press the STOP/RESET button (or cycle oven power off for 30 seconds, then on.) The error will not clear until the internal drive temperature is back withi n range. This may take a few seconds.

1. Check Blower shaft to see if it freely turns.

2. Check t he Oven Air Fi lter and veri fy the Floor Fan is operat ing (If

(Error 5)

the oven is hot). Refer to the bl ower motor/controller test.

Page 43 of 87

OC: Overcurrent Cause Action The current rating of the controller (>200% rated drive

current) had been exceeded. This fault can be caused by any of the following conditions:

1. S hort i n drive outputs 1. V erify that the input and output wiring to the drive are properly

2. Ground fault condition 2. Verify that the output wiring to the motor is not connected to

3. Instantaneous overcurrent resulti ng in greater than 200% rated drive current.

FL: Function Loss Cause Action The remote (external) function loss signal has been

asserted. (Terminals 10 and 11.)

1. The external equipm ent connected to the function loss terminals has failed, or is giving repeated stop requests.

HU: High bus voltage conditi ons Cause Action The D-C bus charged above the IET threshold level of

430 volts.

1. Power Line voltage transient has caused the overvoltage condition to occur.

2. Deceleration rate to fast (Function 2). 3. Check the decel rate (Function 2), and compare with chart on

LU: Low bus voltage conditions Cause Action The D-C bus has fallen below the IET low threshold

level of 180 volts.

1. Momentary loss of input power.

2. Low line voltage on i ncoming power.

Note: If a line dip or mom entary power loss occurs and t he bus level is able to rise back t o the proper range withi n 500 ms., the drive will automatically restart (if the drive was already running when the fault occurred.) If t he drive does not res tart , perform above steps, or cycle oven power off for 30 seconds, then on.

OL: Electronic thermal overload Cause Action The electronic thermal overload trip level has been

exceeded. This fault protects the drive and motor from overheating due to excessive current within a specified period.

1. The Current Limit Setting (Function 5) is not set correctly.

2. Function 14, Elec tronic Thermal Overl oad is not s et correctly to match the motor and controller combination.

3. Motor Shaf t is bound up or hard to turn.

Any of the following codes indic ate a SP500 motor controller failure. Codes Action AdPF, CH, diSc, E Erd, EEOU, EPCH, FSF, In00, In02,

In04, In06, In08, In10, In15, noAd, OLP2, rSF, rEF1, rEF2, SELU, UnOP, 7rAP, r1, r2

Press the STOP/RESET button (or cycle oven power off for 30 seconds, then on).

connected

Ground or any other voltage source.

3. Check motor to insure shaft is free to turn.

Press the STOP/RESET button (or cycle oven power off for 30 seconds, then on.) This fault will not clear until t he func tion los s si gnal is unasserted.

1. Check the external equipment wired to the remote function l oss terminals (10 and 11.)

2. Check function loss connections.

Press the STOP/RESET button (or cycle oven power off for 30 seconds, then on.) The error will not clear until the bus falls below the high bus level.

1. If occurrence seldom, possible no problem.

2. If occurrence is high, suspect incoming power problem or incorrect setting of the SP500 controller (Replace).

4.5.2.

Press the STOP/RESET button (or cycle oven power off for 30 seconds, then on.) The error will not clear until the input line voltage is within the proper range. This may tak e a few seconds.

1. Check incoming power.

2. Check incoming power.

Press the STOP/RESET button (or cycle oven power off for 30 seconds, then on.) The error will not clear until the drive has integrated to the proper range. This may take a few seconds.

1. Verify the value of Function 5.

2. Verify the value of Function 14.

3. Check motor to insure shaft is free to turn.

1. Replac e t he SP500 controller.

Page 44 of 87

4.5 BLOWER OPERATION

4.5.1 How to turn Blower On

1. Set the master switch to ON position.

2. Press MAINTenance key. (Refer to Control Panel Layout, Section 2.4), enter access code, then press ENTER.

3. Press the (BLR) key if LED 7 is off. Press (% BLR) and verify the blower speed increases in 10% increments until 100% blower speed (7050 RPM indicated on BMSC) is achieved. Verify LED 7 (BM) illuminates on the keypad.

4. Verify that the blower motor rotates freely and does not vibrate from imbalance.

5. Verify that the blower shaft rotates in the clockwise direction when viewing the shaft from the front of the oven.

6. Press (BLR) key to stop the blower motor.

4.5.2 Blower Motor Speed Controller Settings

The following is included for setting up a new Motor Speed Controller or if previous settings have changed.

To Access the Controller Setup:

1. W ith oven Master switch ON, select "MAINTenance" key and enter access code.

2. Press the MODE/ENTER key on the Controller to select PROGRAM mode. The Controller PROGRAM Led will be illuminated and the display will show "F-00".

3. Move the up/down arrow keys until the desired function number is displayed.

4. Press the MODE/ENTER key to display the value.

5. Verify the Blower Motor Speed Controller settings by referring to the Controller Nameplate to choose the correct settings from the following chart.

6. Press the up/down arrow keys to change the value, if desired.

7. Proceed to the next function to be verified by pressing the MODE/ENTER key.

8. Press the STOP/RESET key to exit the PROGRAM mode.

Page 45 of 87

BLOWER MOTOR SPEED CONTROLLER SETTINGS

Function D2-3356 Function D2-3356 Function D2-3356

F-00 1 F-11 100 F-22 0 F-01 2.0 F-12 0 F-23 20 F-02 5.0 F-13 OFF F-24 20 F-03 3.0 F-14 100 F-25 20 F-04 120 F-15 ON F-26 10 F-05 100 F-16 OFF F-27 1 F-06 0 F-17 ON F-28 230 ** F-07 120 F-18 OFF F-29 SPd F-08 7050 F-19 OFF F-49 3.10 * F-09 0 F-20 OFF *** F-10 8 F-21 5

* Read only setting. ** Factory set. Do not change. *** PW=257 (Password)

4.6 BLOWER WHEEL REPLACEMENT

If the blower wheel is removed from the motor shaft for any reason it must be replaced with the .150 ± .020 spacing shown.

1. Set the motor on end. Use two 5/32 (.156) x 4” long square key stock as

spacers. The final spacing must measure between .130” and .170” after tightening.

Page 46 of 87

4.7 HEAT EXCHANGER

No More Than 3 Inch of Tubing

The Heater core consists of 18 tubular heating elements, which are divided into sections depending on the model or configuration of the oven. Each individual heating element is rated 450 watts @ 240 VAC. Power input terminals H2 and H3 (Buss bars) are in series with the oven Over-temperature Thermostatic Switch, OT1. The Over-temperature Switch senses the rear exterior surface of the Heat Exchanger and opens when the rear surface of the Heat Exchanger exceeds 600°F (315°C), limiting the maximum fault temperature of the heat exchanger. (This corresponds to a Heat Exchanger temperature of approximately 720°F (382°C)). Two Thermocouples are used for oven temperature control, one measures the Heat Exchanger Core Temperature, HX, and the other measures the Air Temperature entering the Cook Chamber, CC.

The Heat Exchanger is used to:

1. Store energy (heat).

2. Provide thermal uniformity (within the oven).

3. Provide rapid heating of the convection (cooking mode) air.

How to Manually Turn Heaters On:

1. Turn oven on.

2. Press MAINTenance key (MAINT).

3. Enter access code.

4. Press ENTER key.

5. Press the HTR key to alternately turn the heater elements on and off.

Note: LED’s 11 and 16 will come on when the heater elements are on.

CAUTION: DO NOT leave the heaters on for long periods, as the oven will rapidly heat to maximum allowed temperature (approximately 720°F

(382qC)).

REAR VIEW OF OVEN

OTI Capillary

Should Be Under Insulation

HX Thermocouple

Thermocouple Fittin

(100550)

Electronic Compartment

3.50 (88.9)

(102065)

2.50

(63.5)

CC Thermocouple (102065)

(Heat Exch 1)

Page 47 of 87

(20X)

(20X) (20X)

2 4

BUSS BAR

TOP COVER

REAR

HEAT EXCHANGER COVER, BUSS BARS AND CORE ASSEMBLY

ITEM PART NO. DESCRIPTION

1 T100960 NUT, HEX, SS, 10-32 2 T102140 WASHER, FLAT, SS, # 10 3 T102350 WASHER, LOCK, SPLIT, SS # 10 4 T102130 WASHER, FLAT, SS, # 10 X 1” O.D.

5 T7000449 GASKET, RF, COVER-HEAT EXCHANGER 6 T7000454-4 BUSS BAR, INPUT 7 T7000455-4 BUSS BAR, INPUT, 8 T7000456-4 BUSS BAR, INPUT, FRONT

9 T102260 WASHER, LOCK, EXT. TOOTH, SS #10 10 T100802 LUG, RING, 10 GA #8, HI-TEMP 11 T100150 BUSHING, CUP, 2C0504 12 T102120 WASHER, CRANGLAS 6X0004 13 T100160 BUSHING, SHOULDER 2C050

(Heat Exch 2)

Page 48 of 87

4.8 CERAMIC INSULATOR REPLACEMENT

1. Disconnect the oven from the power source.

2. Remove the insulation from the top of the heat exchanger exposing 24 #1032 nuts.

3. Apply a high pressure lubricant to the studs and nuts before attempting removal to keep galling from occurring and studs twisting off.

CAUTION: Use care to ensure that studs are not twisted off. Do not drop anything into the heat exchanger. If hardware is dropped into the heat exchanger, it MUST be removed by fishing from the top or remove the HX and retrieve part and/or broken ceramic pieces.

4. Remove the top baffle weldment by carefully prying under the front lip with a large screwdriver.

CAUTION: Do not damage the RF gasket.

5. Check the insulators at the heater terminals. If they are cracked or broken, replace with new insulators. Tighten the insulator nuts to 6.3 inlb.

CAUTION: If the ceramic insulator is broken, be sure to find all the

ceramic pieces so that they do not end up on someone’s food.

6. Reinstall the heat exchanger top baffle with the wide opening facing front. Reinstall the 24 10-32 nuts, and the oven insulation. Retape the insulation seams.

Ceramic insulator breakage is typically caused by one of two problems.

• Excessive tightening of the insulator assembly. This puts excessive compressive stress on the ceramic insulators.

• Excessive stiffness of the bus bars. This puts high stress on the ceramic insulators when the heat exchanger is bounced around, such as in shipping.

Page 49 of 87

4.9 HEAT EXCHANGER DEFECTIVE MESSAGES

SELF TEST WHILE COOKING CAUSE CORRECTIVE ACTION HX Heat Thermo

OPEN

HX Heat RISE LOW

NOTE:

CC Heat Thermo OPEN

CC Heat RISE LOW

Heaters must be on to check Currents. See 4.6 to turn-on heaters.

COOK TEMPERATURE TOO LOW

HX Thermocouple amplifier indicates open, (999°).

HX Temperature failed to rise 21°F(11.7°C) in 4 minutes

CC Thermocouple amplifier indicates open

CC Temperature failed to rise 14°F(7.8°C) in 2 minutes after HX test passed with 75% Blower on

CC Temperature 84°F (47°C) or more below cook set point after 5

seconds or more into cook cycle

See Thermocouple troubleshooting below.

1. Check heater fuses. (See

8.1), If fuses are blown, check for short to chassis on H1, H2, H3.

2. Check input current to Heat Exchanger. There should be no more than 1 amp difference between readings for each of the 3 phases (See Schematic for rated current).

3. Check operation of the heater relay. (See 8.1)

4. Check voltage across oven Over-Temp. Thermostat, OT1. (See 8.1)

5. Check blower operation (See 4.0-4.5)

6. Check Cook Temp Set Point. (See 2.4.2)

7. Check crimp connections.

8. Replace HX Thermocouple. (See 4.7)

9. Check crimp connections.

10. Replace CC Thermocouple (See 4.7)

11. Check heater fuses. (See

8.1)

12. Check blower operation (See 4.4)

13. Check CC Thermocouple

14. Check blower operation. (See 4.4)

15. Check CC Thermocouple circuitry.

Thermocouple Troubleshooting:

1. Display Reading 77°(25qC) (Room Temperature)

Acceptable condition from a cold start.

2. Display Reading 999°(999qC)

Indicates related thermocouple is open. Check thermocouple connections.

Page 50 of 87

SECTION 5 - MICROWAVE SYSTEM

5.1 MEASURING MICROWAVE RADIATION LEAKAGE

The following RF emissions test must be performed every time a service call is done on a TurboChef oven. Report your findings on the work order.

This test must be done in conformance with 21 CFR, Ch1, Part 1030Performance Standard for microwave and radio frequency emitting products. Part 1030.10 Microwave Ovens. (C) Requirements - (1) Power Density Limit.

“The equivalent plane wave power density existing in the proximity of the external oven surface shall not exceed 1 milliwatt per square centimeter at any point 5 centimeter or more from the external surface of the oven, measured prior to acquisition by purchaser, and, thereafter, 5 milliwatt per square centimeter at any point.”

The following areas are to be measured when performing a RF test.

• Cook Door.

• Filter Door.

• At any point on the outside of the oven fully assembled. (With all covers).

Note: Do not operate the magnetron without a load such as 275 ml of water in the cooking chamber. The tip of the survey meter spacer cone should be touching the oven surface being measured, with the probe handle perpendicular to the surface. Move the cone at a speed of less than 0.5 inch per second.

IN CASE THE OVEN FAILS RADIATION LEAKAGE TEST:

WARNING: If the oven fails radiation test , the oven must be taken out of service immediately until the defect is corrected. In addition, the leakage reading and corrective action must be reported on the work order w hen the defect is corrected and oven placed back in service. If further information is required for this test, please call the TurboChef, Inc. Customer Service Toll Free Number listed on the front of this manual.

(micro check)

Page 51 of 87

5.2 HOW TO TURN MAGNETRONS ON/OFF FOR TESTING

The magnetrons may be turned on/off for testing using the MAINTenance mode. The magnetrons will remain on in this mode as long as the appropriate key is depressed.

Caution: Do not operate the magnetrons for more than 5 seconds without a load in the cooking chamber. A suitable microwave load is 275 ml (9.3 oz) of cold water.

With the oven in the normal “ON” state:

1. Press MAINTenance key.

2. Enter access code.

3. Press ENTER.

4. Press and hold (M12) key. Verify LED 14 (M1) & LED15 (M2) illuminate on the oven keypad LED display.

5. Press the STOP key to return to the normal mode from the maintenance mode.

Note: When energizing the magnetrons, check for fluctuation of RF power on the oven display due to the stirrer blade motion causing the microwave energy to move around in the cooking chamber. The RF power indication should be varying significantly during operation. The RF indication is sampled for 10 seconds. If the difference between the maximum sample and minimum sample is less than 20 units during self-test or 10 units

during cooking, the error message “RF FLUC LOW” will be displayed.

Page 52 of 87

5.3 MICROWAVE COMPONENT LOCATIONS

ITEM PART NO. DESCRIPTION

1 T7001344 INSTALLATION ASSEMBLY WAVEGUIDE SEAL 1A T7001336 ASSY WAVEGUIDE CLAMP 1B T7001333 SEAL, PLUG, TEFLON 1C T7001213 PLUG WAVEGUIDE QUARTZ 1D T102650 WAVE SPRING WASHER 9”

1E T7001321 SEAL, RING, WAVEGUIDE

2 T4000240-2 BLADE STIR MOTOR

3 T102270 WASHER, STAR, CRES #6

4 T101590 SCREW, PPH, SS, #6-32X.38 LG

5 T102380 WASHER, SPLIT, LOCK #6

6 T100860 MAGNETRON (HITACHI 2M121A)

7 T100690 INSULATOR KLIXON

8 T102070 THERMOSTAT, KLIXON

9 T101683 SCREW, PPH, TYPE F#5X.25 LG

10 T7001284-1 ASSY STIRRER MOTOR 10A T7001290 SHAFT, STIR MOTOR 10B T7001285 ASSY, STIR MOTOR PLATE 10C T100891 MOTOR, SYNCHRONOUS, 6.0/7.2 RPM 10D T102300 WASHER, INT. TOOTH LOCK #4 10E T101520 SCREW, PPH, 4-40X.25 LG

10F T102716 CONNECTOR, PLUG

10G T102035 PIN, CRIMP, MALE

11 T102360 WASHER, SPLIT, LOCK #2

12 T101490 SCREW, PPH, SS, 2-56X.18 LG

13 T2656148-7 CONNECTOR, RECEPTACLE

14 T7000408-3 ASSY, RF CABLE, RG405

15 T7001226-4 TUBE, SHIELD (MAG 1)

16 T7001226-3 TUBE, SHIELD (MAG 2)

17 T102350 WASHER, SPLIT, LOCK #10

18 T102140 WASHER, FLAT, #10

19 T1799 SCREW, COMMON TYPE ZINC PLATED #10

20 TDB FLANGE NUT, METRIC, M5

Page 53 of 87

MICROWAVE CHAMBER

(2X)

5(2X) 3(2X)

DETAIL A

SEE DETAIL A

(2X)

10A

10D

10E

10B

10C

171819

Magnetron Side View

10F

10G

(Micro Comp)

Page 54 of 87

5.4 MICROWAVE ERROR MESSAGES

SELF TEST WHILE COOKING CAUSE CORRECTIVE ACTION Mag 1(2)

CURRENT LOW

Mag 1 RF FLUC LOW

Mag 1(2) THERMOSWMag THERMOSWDetected MAG1 or

Mag CURRENT LOW

Mag RF FLUC LOW

Note: Stirrer motor operates only when magnetron filaments are are ON.

Remove magnetron fuses

when inspecting stirrer motor operation.

Did not detect current to the magnetron transformer 1(2).

If magnetrons are ON at least 15 sec. During cook, RF power has failed to fluctuate 10 in 10 sec.

MAG2 thermal switch, (KLXM1, KLXM2) open. Implying the magnetron case temperature is

above 212°F (100°C).

1. Check magnetron fuses. (See 8.1). If fuse(s) are blown, check Monitor relay and interlock switch operation (LEDs 1-6).

2. Check Mag and Filament relay operation.

3. Check Magnetron, magnetron transformer, filament transformer capacitor, and diode. (See

5.5-5.10)

Note: If a magnetron is found to be defective, the failure may be due to moisture and/or other contaminants in the waveguide cavity which causing the magnetron to overheat due to high reflected power. If moisture is found in the waveguide cavity, the cavity must be cleaned and resealed.

See 5.11 for additional information.

1. Check RF power detection cable. (See 5.3)

2. Check RF sensor. (See

5.11)

3. Check operation of the stirrer motor Check for any loose wires in the circuit.

4. Check attachment of stirrer blade.

5. Check for loose wires.

6. Change I/O CCA. (See 8.1)

7. Check for failed waveguide seal.

1. Check MAG1, MAG2 over temperature switch.

2. Check for loose wiring in the circuit.

3. Check Air Filter to see if is stopped up or dirty.

4. Check proper operation of magnetron blower (Note: Mag. fan operates only when magnetrons are on.)

Page 55 of 87

5.5 MAGNETRON

COOLING FINS

MAGNETRON CASE

ANODE SUPPLY TERMINAL

The magnetrons emit RF energy that is coupled to the cook chamber via the waveguide assembly. The RF energy generated by the magnetron occurs at a frequency of 2450 MHz.

Caution: Do not attempt to measure the magnetron voltages with a typical voltmeter. (Voltages are approximately 4000-4500 VDC.)

ANTENNA

HIGH VOLTAGE

FILAMENT TERMINALS

(Magnetron)

How to check a magnetron for open or shorted filaments:

1. Disconnect the ac power source and discharge the High Voltage Capacitors.

2. Isolate the magnetron from the circuit by removing the wires from the F and FA terminals.

3. An ohmmeter connected between the filament terminals (F, FA) should indicate a reading of less than 1 Ohm.

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

Page 56 of 87

5.6 HIGH VOLTAGE (HV) MAGNETRON TRANSFORMERS

The high voltage magnetron (anode) transformer has a primary winding and two secondary windings. The filament secondary of the anode transformer is not used. The primary winding of the anode and filament transformers have 208/240 VAC applied from the line voltage circuit. The secondary filament transformer winding (4.6 VRMS @ 14 Amps) is connected to the filament in the magnetron (F, FA terminals) to supply magnetron filament power. The secondary HV Anode winding (2250 VPK @ 0.83 Amps) is doubled (converted to -4500 VDC @ 0.415 Amps) by the HV diode and capacitor and connected to one side (FA terminal) of the filament. The Magnetron Anode is grounded. The cathode in the magnetron is the filament. The anode to (cathode and) filament is supplied by operating the filaments at a negative potential of 4500 VDC.

To change or confirm frequency see Appendix B for Japanese HV transformer.

To change or confirm voltage see Appendix D for filament transformer.

240VAC

PRIMARY

200/208VAC

PRIMARY

FILAMENT TRANSFORMER

4.6VAC SECONDARY

BACK VIEW

3 2

FRONT VIEW

240V

200/208V

208-240

VAC INPUT

PRIMARY COMMON

HV ANODE WINDING (SECONDARY

T4 FILAMENT TRANSFORMER

3 2

T3 OR T4

T1 OR T2

ANODE TRANSFORMER

T1 OR T2

NOT USED

1.05uF (60Hz)

1.2uF (50hZ)

50Hz

60Hz

CAPACITOR

15KV

HV DIODE

ANODE TRANSFORMER

REAR VIEW

50Hz 60Hz

MAG1 OR MAG 2 4500 VPK 415 MA

FILAMENT WINDING

(SECONDARY)

208-240 VAC (PRIMARY)

(Transformer)

Page 57 of 87

TRANSFORMER SPECIFICATIONS

2X 0.250

.12

T1 or T2 Anode Transformers T3 or T4 Filament Transformers

Primary DCR 0.58 Ohm. Secondary DCR: (5-6) 46.39 Ohm

(5-7) 54.00 Ohm Input Voltage : 208-240 VAC, 50/60 HZ Input Current: 9.0 Amps RMS Anode Voltage: 4500 VDC Peak @

0.415 Amps

Primary DCR (1-2) 23.2 Ohm

(1-3) 27.8 Ohm Secondary DCR: (4-5) .020 Ohm Input Voltage : 208/240 + 10%

50/60 HZ Input Current: 0.42 Amps @ 208 VAC

0.35 Amps @ 240 VAC

Filament Voltage: 4.6 VAC @ 14 Amps

How to check a transformer:

1. Disconnect the power source and discharge the capacitor.

2. Isolate the transformer from the circuit. (Wires are labeled but remember where they go)

3. Check impedance of the primary and secondary windings. ( See above.)

4. Filament winding should read less than 0.1 ohms.

5. Reconnect wires.

5.7 HIGH VOLTAGE DIODE

The High Voltage Diode is an assembly constructed by connecting several 10001500 volt semiconductor diodes in 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 2250 VPK, the high voltage capacitor is charged to 2250 volts. When the high voltage winding starts to go toward negative, the High Voltage Diode becomes non-conducting with the charged High Voltage Capacitor in series with the High Voltage Winding. When the transformer gets to its negative peak of -2250 VPK, the voltage applied to the filament is negative 4500 volts.

0.75

0.42

0.75

3.00

1.68

4X R FULL

0.32

0.16

0.31

1.22

0.25

HIGH VOLTAGE DIODE

*8FKQFG

Page 58 of 87

How to check a diode: Caution: Do not attempt to measure HV directly.

1. Disconnect the oven from the power source.

2. Isolate diode from circuit.

3. Connect the meter leads to the diode terminals.

4. Infinite resistance (open) should be indicated in the reverse direction.

5. Resistance readings in the forward direction may be indeterminate. *

6. If there is continuity in both directions (shorted diode). Due to the HV diode consisting of approximately 15 X 1000 volt diodes in series

the forward diode drop is approximately 9 volts. A normal low voltage ohmmeter will not provide sufficient voltage in the resistance ranges to measure an impedance in the forward direction of the High Voltage Diode.

High Voltage Field Test Procedure

1. Locate the diode to test, make sure that the magnetron circuit is not powered up.

2. Carefully remove the wire going to the capacitor from the diode - terminal.

CAUTION: The capacitor can maintain a charge for a long time.

3. Connect a 100 ohm, 10 watt resistor from the power diode (D5 Cathode) on the I/O board (+24.0 volts) and the (-) lead of the diode.

4. Measure the voltage between the Diode (-) terminal and chassis ground (or the other side of the high voltage diode) using a multimeter on the DC range.

a) If the voltmeter reads zero (less than .3 volts) the diode is shorted. b) If the voltmeter reads greater than 15 volts the diode is open. c) The following should be considered good diodes:

Voltmeter Reading Diode Part Number

6.6 to 7.8 volts HVP15

6.6 to 7.8 volts HVCA

8.2 to 9.8 volts GLC 32

Theory:

The 15,000 volt High Voltage Diode, 100480, is really an assembly of several lower voltage diodes in series. Different manufacturers of the high voltage diode assembly may make it up using different number of diodes. For instance, 10 x 1,500, 12 x 1,250 or 15 x 1000 volt diodes could be used to make up the high voltage diode assembly.

Page 59 of 87

The test above provides approximate 180 milliamps of current in the diode’s

(

)

forward direction and measures the voltage drop. Each diode in the assembly should have approximately .55 to .65 volts drop under these conditions. By measuring the voltage drop, the number of good diodes can be estimated to see if any of the series diodes are shorted.

The following chart lists the typical voltage drop expected across the high voltage diode when conducting 180 milliamps of current.

# Voltage Drop # Voltage Drop # Voltage Drop

1 .55 to .65 volts 7 3.8 to 4.6 volts 13 7.1 to 8.5 volts 2 3.8 to 1.3 8 4.4 to 5.2 14 7.7 to 9.1 3 1.1 to 2.0 9 4.9 to 5.9 15 8.2 to 9.8 4 1.6 to 2.6 10 5.5 to 6.5 16 8.8 to 10.4 5 2.2 to 3.3 11 6.0 to 7.2 17 9.3 to 11.1 6 2.7 to 3.9 12 6.6 to 7.8 18 9.9 to 11.7

100 Ohm 10W

24.0 VDC

5.8 HIGH VOLTAGE CAPACITOR

The High Voltage Capacitor is part of the voltage doubler which stores the transformer peak voltage thus creating a voltage doubler to supply the magnetron with a pulsed -4500 volt dc anode voltage. The capacitor is either

1.05 µF for 60 Hz power or 1.2 µF for 50 Hz power.

CAUTION: After removing the oven from power and prior to servicing the oven, discharge the capacitor. Never assume the discharge resistor internal to the capacitor has completely discharged the capacitor.

1.05uf 2500V 60Hz 70C

1.2uf2500V60Hz70C

AEROVOX N50H2510GR

AEROVOX N50H2512GR

INTERRUPTERS

CAPACITOR

DISCHARGE RESISTOR

1.05 .15

Elec Conn

INTERRUPTERS

1.05 F CAPACITOR DISCHARGE RESISTOR

.15 F CAPACITOR

DISCHARGE RESISTOR

SINGLE 1.08 OR 1.20 F

(Early D3 Models)

DUAL 1.05 OR .15 F

(Later D3 Models)

(HV capacitor)

Page 60 of 87

How to check a capacitor:

(Mag Over T em p Sw)

1. Disconnect the oven from the power source.

2. Isolate the capacitor from the circuit.

3. Fully discharge the capacitor.

4. Connect the ohmmeter between the capacitor terminals. The meter should indicate a low impedance and then slowly return to infinite resistance.

5. Reverse the ohmmeter leads. Repeat step 4.

6. Check each terminal to case. Infinite resistance (open) should be indicated.

5.9 MICROWAVE MODE STIRRER

The microwave mode stirrer and associated stirrer blade changes the modal pattern in the cook chamber to reduce hot spots of microwave energy from occurring, thus providing more even cooking. The stirrer motor is a 240 VAC synchronous motor that turns at 7.2 rpm (6 rpm in 50 Hz units).

MOTOR

6.0/7.2 RPM

STIR MOTOR WIRING DIAGRAM

RED RED

240 VAC 50/60 Hz

5.10 MAGNETRON OVER-TEMPERATURE SWITCH

The Magnetron Over-temperature Switch is designed to protect the magnetron from overheating. During normal operation, the switch is closed . The overtemperature switch opens when the magnetron case exceeds 212°F (100°C). Overheating may occur due to a dirty or blocked Air Filter, a failed Magnetron Cooling Fan or a contaminated waveguide cavity.

(Stirrer)

Page 61 of 87

5.11 RF OUTPUT MONITOR CIRCUIT

A RF sensor in the microwave waveguide assembly detects a portion of the radio frequency (2450 MHz) energy emitted during the operation of the magnetron(s). A RF Cable Assembly connects the RF sensor to a SMA connector on the I/O Circuit Card Assembly, CCA. On the I/O Circuit Card Assembly, the RF energy is detected and amplified. The amplifier gain is controlled by R10 on the I/O CCA. The analog signal is then routed via a flat cable to the Control CCA where it is digitized by the microprocessor for control and display. Note: RF readings are displayed in MAINTenance and Diagnostic displays. The readings, measured over a 10 second period, must fluctuate a minimum of 20 units to pass self-test and 10 units to pass the on-line tests (while cooking). The Mode Stirrer rotates at

7.2 rpm for 60Hz and 6 rpm for 50Hz.

How to check the RF Sensor

The RF Sensor is an electrostatic type.

1. Disconnect the RF coax cable from the I/O CCA board at the SMA connector.

2. The resistance between the center conductor and shield as measured at the SMA connector should be infinite (open).

3. Any measured resistance indicates the RF sensor may be defective or may require cleaning to remove any carbon deposits. Also disconnect the coax cable from the RF sensor to check that each has infinite resistance between the center connector and coax shield or probe body. Also check that the SMA

connector’s center pins are properly positioned in the connector. Replace or clean the defective part.

5.12 MAGNETRON POWER VERIFICATION CAUTION: Use care in disposing of hot water.

Check the combined magnetron power as follows:

1. Place a shallow microwave safe dish with 1000ml or 33.8 oz of cold water,

approximately 40°F (4°C) in the oven.

2. Measure and record the initial water temperature.

3. Using MAINTenance mode and the M12 key, turn both magnetrons on for 60

seconds.

4. Measure the final water temperature. The water temperature rise should be a

minimum of 450°F (25°C).

Page 62 of 87

M/W PLUG SEAL

CCW INCREASE, CW DECREASE GAIN

(SHOWN REMOVED)

RF SIGNAL IS DIGITIZED BY PROCESSOR AND DISPLAYED

FLAT CABLE CARRIES ANALOG SIGNAL TO CONTROL CCA

R10 (OR R17) ADJUSTS GAIN,

MICROWAVE WAVEGUIDE ASSEMBLY

FRONT

OF OVEN

M/W STIRRER MOTOR

RF output monitor troubleshooting information:

1. Rf reading of 0.

a) Rf cable is defective, loose or disconnected. b) I/O CCA failure.

2. If fluctuations exist but are not fast enough (compared to 10 seconds) check

for:

RF SENSOR

PICKS UP

SAMPLE OF

M/W ENERGY

RF COAX CABLE

MAGNETRON ANTENNA RADIATES M/W ENERGY

RF OUTPUT MONITOR CIRCUIT

RF IS DETECTED & AMPLIFIED ON CCA

(RF output)

a) Defective stirrer motor. b) Microwave stir blade not turning due to loose setscrew or attaching screw.

3. If fluctuations exist but are low, check for:

a) Carbon or other trash covering Rf sensor in waveguide cavity. b) Defective Rf detector or amplifier on I/O CCA.

Page 63 of 87

5.13 WAVEGUIDE SEAL INSTALLATION

(#4)

(#3)

1. Set waveguide seal ring (#5) face down on a flat clean surface.

(#5)

2. Place the two wave washer springs (#4) into the waveguide seal ring (#5).

NOTE: Align the breaks on the two wave washer springs.

(#5)

3. Place the quartz waveguide plug seal (#3) on the wave washer springs (#4).

(wave 1)

(wave 2)

(#3)

(#4)

(#5)

(wave 3)

4. Fit the Teflon waveguide plug seal (#2) on the 9” launcher tube.

NOTE: There is a groove on the Teflon seal that fits on the edge of the launcher tube.

Seal

(#2)

Tube

(wave 4)

5. Carefully place the assembly of items #5, 4 and 3 on the Teflon waveguide

plug seal.

(#3)

(#5)

(#2)

(wave 5)

Page 64 of 87

6. Attach the waveguide clamp top ring on the seal ring tabs and lightly tighten

the clamp so the assembly can be compressed.

(#1)

(#3)

(#5)

Center clamp ring adjustment screw

Seal Ring Tabs

Top ring determined by notch

between seal ring tabs

(wave 6)

7. Gently tap down on the seal ring with a rubber mallet to compress the

springs, Teflon seal and quartz plug together. Tighten the clamp to 20 inch lbs.

CAUTION: DO NOT hit the quartz.

Page 65 of 87

SECTION 6 - COOK DOOR ASSEMBLY

SEE DETAIL B

16A

16B

16C

SEE

DETAIL A

6.1 COOK DOOR AND RELATED ASSEMBLIES

17(2X)

COOKING CHAMBER

1(2X) 2

26(2X)

16 (8X)

(2X)

12 (2X)

(2X)

13 (2X)

4(3X)

5(6X)

VIEW D-D

10 (4X)

D D

(LEFT)

18 (2X)

18 (2X) 19

(2X)

(RIGHT)

(6X)

7(2X)

DETAIL A



DETAIL B

(Cook door)

Page 66 of 87

iTEM PART NO. DESCRIPTION

1 T101665 SCREW, PPH, SS, 8-32 X .38. 2 T102320 WASHER, LOCK, INT. TOOTH, SS, # 8 3 T100910 NUT, ACORN, HIGH CROWN, SS, 1/4-28 4 T101385 SCREW,HEX. HD, GRADE 8, 1/4-28 X 1.25 5 T102330 WASHER, LOCK, INT. TOOTH, SS, 1/4 6 T102200 WASHER, FLAT, SS, 1/4 7 T101730 SCREW, SHOULDER, 10-32, φ .25X.125 8 T101900 TORSION SPRING, LEFT

9 T101890 TORSION SPRING, RIGHT 10 T101855 PRECISION SHAFT φ .375 X 2.0 11 T7000288 SLIDE 12 T7000422-1 RAIL, SLIDE, FRONT ASSEMBLY 13 T7000423-1 RAIL, SLIDE, REAR ASSEMBLY 14 T102320 WASHER, LOCK , INT. TOOTH, SS, #8 15 T101747 SCREW, SKT. HD, SS, 8-32 X .50 16 T7000590-1 BEARING ASSEMBLY

16A T7000428 SPACER, BEARING 16B T7000362 ROLLER, SLIDE 16C T7000427 BEARING, SPOOL

17 T7000429 LATCH BAR, RAIL 18 T101135 PIN, DOWEL, φ .125 X .68 LG. 19 T7000430 LATCH RAIL 20 T101875 SPACER 21 T7000438-1/2 SPRING RIGHT (-1)/ SPRING LEFT(-2) 22 T7000214 RING 23 T7000270 COVER * 24 T7000249 HANDLE WELDMENT 25 T7000215 MOVEABLE WALL 26 T7001169 DOOR PIN RETAINING PLATE 27 T102400 WASHER, LOCK, SPLIT, SS, ¼

28 T101309 RING, RETAINER 29 T102820 SPRING, COMPRESSION 30 T7001247 PIN, LATCH, DOOR COVER 31 T7001245 GASKET DOOR COVER 32 T7001244 GASKET DOOR INNER 33 T7001246 GASKET ENVIRONMENTAL, DOOR 34 T7000478-2 TUBING ∅ 68”

35 T7000478-1 TUBING ∅ .25” 36 - RTV 37 - PRIMER

NOTES: When replacing gaskets it is imperative that the groove be completely

cleaned and primed before installing the new gasket.

* Apply primer (item 37) to interior of outer gasket groove (only). Let dry completely.

Apply 6-8 small drops of RTV (item 36) equally spaced inside groove. Insert RF gasket (item 31) into groove before RTV starts to setup.

Page 67 of 87

6.2 COOK DOOR AND INTERLOCK SWITCH ADJUSTMENTS

Door handle alignment is performed with the door closed and latched. The 0.110 (2.8mm) dimension is adjusted by adding washers, item 9. Adjust the door pressure on the door flange by compressing the 1.00 inch long Die Spring to the

0.875 (22.2mm) dimension shown. Door Switch alignment is performed with the door closed and latched. The switch

actuators should be centered in the over-travel region of the switch, (between the point that the switch closes and where the switch actuator contacts the switch case). There is one cook door monitor switch (right side) with the primary cook door interlock on the right and the secondary cook door interlock on the left.

CAUTION: If any adjustments are made to the cook door or interlock switch assembly a microwave leakage test must be completed.

COOK DOOR PRIMARY (RIGHT SIDE)

COOK DOOR SECONDARY (LEFT SIDE)

(RIGHT & LEFT SIDE) (RIGHT & LEFT SIDE)

7 6

.875 025 (22.2 0.6)

± . ±

COOK DOOR MONITOR (RIGHT SIDE ONLY)

.110 .045 (2.8 1.1)

±±

COOK DOOR LATCH/INTERLOCK SWITCH ASSEMBLY

(Right Side Shown)

ITEM PART NO. DESCRIPTION

1 T7000088 ROD, U-SUPPORT

2 T101010 1/2-13 NUT, JAM

3 T100940 1/2-13 NUT, HEX

4 T102015 MICROSWITCH, MONITOR, (CDM)

5 T102015 MICROSWITCH, INTERLOCK, (CDP)/(CDS)

6 T7000563-1 SWITCH BRACKET, RIGHT

7 T7000563-2 SWITCH BRACKET, LEFT

8 T101880 DIE SPRING, 1” FREE LENGTH

9 T102253 1/2 WASHER, FLAT, SMALL PATTERN 10 T7000567 BEARING, FLANGE, MODIFIED

(Door Latch)

Page 68 of 87

SECTION 7 FILTER DOOR SWITCH LOCATION / ASSEMBLY

RIGHT SIDE

FDS

FDM

(4X)

COOKING CHAMBER

FILTER AREA

FDP

(4X)

LEFT SIDE

FILTER DOOR LATCH/INTERLOCK SWITCH ASSEMBLIES

ITEM PART NO. DESCRIPTION

1 T7000529-2 SWITCH PLATE, LEFT

2 T7000529-1 SWITCH PLATE, RIGHT

3 T102160 WASHER, FLAT, SMALL PATTERN #4

4 T102370 #4 WASHER, LOCK, SPLIT

5 T101555 4-40 X .75 LG. SCREW, PPH, SS

6 T102255 3/8 WASHER, FLAT, SMALL PATTERN

7 T7000530-2 STIFFENER PLATE, FILTER DOOR, LEFT

8 T101790 10-32 X .75 LG. SCREW, PPH, SS

9 T102350 #10 WASHER, LOCK, SPLIT 10 T102140 #10 WASHER, FLAT 11 T100400 BEARING 12 T7000530-1 STIFFENER PLATE, FILTER DOOR RIGHT 13 T102015 MICROSWITCH

NOTE: SHOWN WITH FILTER DOOR, 700-0615, REMOVED.

(Filter door)

Page 69 of 87

SECTION 8 CONTROLS

8.1 ELECTRICAL ENCLOSURE ASSEMBLY

1514

(6X)

(2X)

(5X)

(2X)

(6X)

ELECTRICAL ENCLOSURE ASSEMBLY

ITEM PART NO. DESCRIPTION

1 T100540 FILTER, EMI

2 T101268 RELAY, POWER

3 T101017 SWITCH, THERMAL LIMIT, 600°F, OT1

4 T7000399 CABLE, EXTENSION, RS-232

5 T100440 CONTROLLER, MOTOR, SP 500

6 T80849 I/0 CIRCUIT CARD ASSY, D1B/D2B SERIES

7 T101205 POWER SUPPLY

8 T102085 THERMOSTAT 120°F, OT2

9 T100490 DISTRIBUTION BLOCK, MB4/6.L3 10 T100590 FUSE HOLDER, 30A, MB10/22SF 11 T100710 JUMPER BAR, 10 POLE 12 T100491 DISTRIBUTION BLOCK, MB6/8.L3 13 T100470 END STOP, DIN RAIL

- T100595 FUSE 12A, UL CLASS CC (KLKR-12)

- T100615 FUSE 30A, UL CLASS CC (KLKR-

14 T7000407-3 RIBBON CABLE, 50 COND X 36”, W21

12(4X)

(Board)

Page 70 of 87

8.2 ELECTRICAL ENCLOSURE DIAGNOSTIC MESSAGE

SELF TEST WHILE COOKING CAUSE CORRECTIVE ACTION

EC Temp ___ °F

Electrical Enclosure Temperature above 140°F

1. Check oven air filter.

2. Check cooling fan operation.

3. Checking cooling air pathways.

8.3 DISPLAY AND KEYPAD ASSEMBLY CAUTION: When a procedure calls for replacing a Circuit Card Assemble,

(CCA), or the EPROM IC, the power switch must be OFF or permanent damage may result.





;





; 



;



;



'LVSOD\

DISPLAY AND KEYPAD ASSEMBLY

ITEM PART NO. DESCRIPTION

1 T7000269 CONTROLLER, ENCLOSURE 2 T7000328 KEYPAD 3 T80846 CONTROLLER CIRCUIT CARD ASSY, D1B/D2B SERIES

**4 T7000650 IC, EPROM, SOFTWARE NOTE: PLEASE

SPECIFY SOFTWARE VERSION WHEN ORDERING 5 T101520 4-40 X .25 LG. SCREW, PPH, SS 6 T102370 #4 WASHER, SPLIT LOCK 7 T102240 #4 WASHER, FLAT, SMALL PATTERN 8 T101420 4-40 X .25 LG. SCREW, PFH, 100° 9 T101920 STANDOFF, FEM/FEM HEX ALUM.

** NOTE: WHEN REPLACING THE EPROM IC, ITEM 4, MAKE SURE POWER IS OFF, THE IC IS NOT INSERTED UPSIDE

DOWN, AND ALL PINS INSERT INTO THE MATING CONNECTOR ON THE BOARD CORRECTLY. IF THESE PRECAUTIONS ARE NOT FOLLOWED, PERMANENT DAMAGE TO THE IC MAY RESULT.

Page 71 of 87

SECTION 9 MAGNETRON FAN / COOLING FAN / TRANSFORMERS /

(S/N 080399IO102S and Later)

DIODES/ CAPACITORS

REF

CR 2

CR1

(4X) (4X) (4X)

(2X) (4X)

(2X) (2X)

(4X) (4X)

(4X)

NEWER MODELS ONLY

(4X) (4X)

(2X)

(4X)

4 5

(T2) (FL2)

(T1)

(FL1)

FLOOR MOUNTED ELECTRICAL PARTS

ITEM PART NO. DESCRIPTION

1 T100240 CAPACITOR, RUN, 2 uF, 400 V 2 T7000431 BRACKET, ROTARY FAN 3 T100090 BLOWER, COOLING, 240 VAC, 50/60 HZ

- T101436 SCREW, PFH , 82°, SS, 10-32 X .38 4 T101747 SCREW, SKT. HD, SS, 8-32 X .500 5 T102275 WASHER, LOCK, EXT. TOOTH, SS, #8 6 T102093 TRANSFORMER, MAGNETRON ANODE 208/240VAC 7 T100540 FILTER, EMI (UNDER TRANSFORMERS) 8 T100480 DIODE, HIGH VOLTAGE, 15,000 V 9 T101570 SCREW, PPH, SS, 6-32 X .500

10 T102380 WASHER, SPLIT, LOCK, SS, #6 11 T102250 WASHER, FLAT, SMALL PATTERN, #6 12 T100200 CAPACITOR, HV, 1.05 uF, 2500 V (US)

- T100205 CAPACITOR, HV, 1.2 uF, 2500 V (EC)

- T101015 CIRCUIT BRKR/SWITCH, 40 AMP (US)

- T101016 CIRCUIT BRKR/SWITCH, 25 AMP (EC)

13 T100130 BRACKET, CAPACITOR

(Elec Parts)

Page 72 of 87

14 T100220 TERMINAL CAP, CAPACITOR

(not used on models produced after S/N 080399IO101S)

15 T102170 WASHER, FLAT, SS, # 6 16 T101590 SCREW, PPH, SS, 6-32 X .38

- T101630 SCREW, PPH, SS, 8-32 X .50

- T102390 WASHER, SPLIT LOCK, SS, #8

- T102180 WASHER, FLAT, SS, #8

- T100080 BLOWER, MAG., 240 VAC, 50/60 HZ

17 T100239 CAPACITOR, 1.0 uF, (EBM) 18 T100081 BLOWER 230 VAC, 50/60 HZ (EBM) 19 T7001264 BELT, DUAL TRANSFORMERS

- T101014 60A CIRCUIT BREAKER SWITCH

- T101015 40A CIRCUIT BREAKER SWITCH

- T101016 25A CIRCUIT BREAKER SWITCH

20 T100206 CAPACITOR, 1.05 + 0.15 uF, 2500V, 3 TERMINAL 21 T7001268 BRACKET, CAPACITOR, 3 TERMINAL

Page 73 of 87

SECTION 10 TROUBLESHOOTING

10.1 COMMON DOOR RELATED PROBLEMS Symptom

Oven displays cook door open or filter door open when cook and filter doors are closed.

Corrective Action

1. Requires cook door or filter door alignment. (too much play)

2. Door handle latch mechanism not functioning properly.

3. Defective door handle.

4. Defective microswitch or need proper alignment. (check all interlock switches

in the oven)

Symptom

Oven door difficult to open.

Corrective Action

1. Verify oven door ring does not interfere with screen basket inside the oven.

2. Verify door slide rail hardware is tight and bearings are rolling freely.

3. Verify bearing assemblies are not excessively worn or damaged.

Symptom

Oven door difficult to open and close.

Corrective Action

1. Verify movable wall is not loose and is correctly adjusted.

2. Verify cooking ring is not loose.

3. Inspect slide bearing assemblies. If bearing assemblies are dirty, clean and

reinstall. If spools are defective, replace with new spools.

4. Verify rod assemblies are not loose or misadjusted.

5. IF DOOR HANDLE IS NOT CLOSING PROPERLY, REMOVE DOOR

COVER If door handle is not closing properly, remove door cover and ensure door springs are not broken.

6. If door does not close completely:

a) Remove door cover and ensure that the three center bolts and internal

acorn nuts are tight. If loose the door must be readjusted to the mating

flange on the oven. b) Check door bottom cover hardware for tightness. c) Adjust door latch mechanism. d) Check moveable wall to ensure that it has not slid back causing

interference.

Page 74 of 87

Symptom

Oven door detaches from oven.

Corrective Action

1. Verify door slide rail hardware is tight and door stops are working properly.

2. Replace door stops.

10.2 MISCELLANEOUS PROBLEMS Symptom

No display.

Corrective Action

1. Check auxiliary fuses.

2. Power supply 240 VAC input and 24 VDC output.

3. Check for a possible short in the circuit for the power supply (chassis is 24

VDC ground

4. Check for loose connectors or wires.

5. Check for proper installation of software (EPROM).

Symptom

Keeps blowing magnetron fuses.

Corrective Action

1. Check for correct f u se type.

2. Check interlock switch operation.

3. Check for proper door alignment or filter door.

4. Check for possible shorted magnetron capacitor diode or magnetron tube.

5. Shorted monitor relay or magnetron power relay. (If blowing both fuses)

Symptom

Magnetron fan not operating properly.

Corrective Action

1. Check for any loose wires in the circuit.

2. Check for continuity and voltage at the connector.

3. Check proper connector going to MAG fan motor.

4. Defective motor or capacitor

Page 75 of 87

Symptom

Stirrer motor does not rotate (RF level does not change when magnetrons are on)

Corrective Action

1. Def ective stirrer motor.

2. Check for proper operation of the magnetron relay.

3. Check for continuity and voltage at the stirrer motor connector (Refer to

proper schematic)

Symptom

Displayed temperatures have erratic fluctuations.

Corrective Action

1. Check for any loose wires on thermocouple circuit.

2. Check for RF leakage at the magnetron cavity (RF energy might be reflecting

back to the I/O board disturbing proper functioning of the amplifier).

3. Check for proper installation of the thermocouples. (Refer to Section 4).

Symptom

Oven turns on/off. (resetting itself and going into the self test terminates cook cycle before time reaching ∅)

Corrective Action

1. Check I/O and control (display) circuit card assembly ribbon cables.

2. Check power supply input and output.

3. Check all connections at the interlock switches for any erratic behavior (such

as loose wires or open switches).

4. Check incoming power to the oven.

5. Loose socket on CCA board.

6. Check RF leakage around controls, door and magnetrons.

Page 76 of 87

SECTION 11 DIAGNOSTIC INFORMATION

The following information is provided to aid in location of faults in the oven.

Status LED LED Name Description

definitions (Refer to Status LED Layout)

1 CDP Cook Door Primary interlock + Filter Door Primary interlock switches

closed.

2 CDS Cook Door Secondary interlock + Filter Door Secondary interlock

switches closed.

3 CDM Cook Door Monitor interlock + Filter Door Monitor interlock switches

closed.

4 FDP Filter Door Primary interlock switch closed. 5 FDS Filter Door Secondary interlock switch closed. 6 FDM Filter Door Monitor interlock switch closed. 7 BLR Blower Motor Controller on. 8 - Not Used

9 - Not Used 10 - Not Used 11 HXR Heat Exchanger Power Relay closed. 12 M1T Magnetron 1 Temperature below maximum (212°F)(100°C.

13 M2T Magnetron 2 Temperature below maximum (212°F)(100°C. 14 M1I Magnetron 1 Current. Input to Magnetron 1 transformer above 7 amps. 15 M2I Magnetron 2 Current. Input to Magnetron 2 transformer above 7 amps. 16 HXI Heat Exchanger Current above 7 amps (In phase measured.)

Interlock and Monitor Switch Locations

Cook Door Primary Interlock (CDP) Right side top Cook Door Secondary Interlock (CDS) Lef t side top Cook Door Monitor (CDM) Right side bottom Filter Door Primary Interlock (FDP) Right side top Filter Door Secondary Interlock (FDS) Left side top Filter Door Monitor (FDM) Left side bottom

Magnetron Circuit Parts Locations

T1 Right most transformer. T2 Left most transformer. T3 Front most transformer. T4 Rear most transformer. C1 Front most capacitor. C2 Rear most capacitor. CR1 Front most diode. CR2 Rear most diode. MAG1 Right most magnetron. MAG2 Rear magnetron.

Page 77 of 87

Notes on Thermocouple Troubleshooting

1. Display Reading 77°(25°C) is acceptable when oven is cold.

2. Display Reading 999°(999°C) indicates related thermocouple is open

3. Thermocouples can be tested by placing in boiling water and checking display for approximately 212°F(100°C).

Electrical Schematics

The following electrical schematics are provided to aid in troubleshooting the various ovens. A schematic may also be found behind the control panel of the oven. The correct schematics for the various models are defined below:

Model Schematic Title

D3-A-5/6D4 700-0376-1 Schematic, US Oven, 3 Ø, 4W, 208/240 VAC, 50/60 Hz D3-S-5/6S3 700-0376-4 Schematic, US Oven, 3Ø, 3W, 208/240 VAC, 50/60 Hz D3-E-5/6Y5 700-0376-2 Schematic, European Oven, 3Ø, 5W, 400-415 VAC, 50/60 HZ D3-J-5/6D4 700-0376-3 Schematic, Japanese Oven, 3Ø, 4W, 200 VAC, 50/60 HZ

Page 78 of 87

Page 79 of 87

Page 80 of 87

Page 81 of 87

Page 82 of 87

SECTION 12 LIMITED WARRANTY FOR “D” SERIES OVENS

TURBOCHEF TECHNOLOGIES® D3 Model

ORIGINAL EQUIPMENT LIMITED WARRANTY

TurboChef by Blodgett warrants to the original purchaser its D3 model to be free from defects in material and workmanship for which it is responsible. Blodgett’s obligation under this warranty shall be limited to

repairing or replacing without charge any part which is found to be defective within the earlier of one (1) year from the date of installation or 13 months from the date of shipment from our factory, together with the labor costs incurred in each repair or replacement, provided equipment has been unaltered, and has been properly installed, maintained, and operated in accordance with the Owner’s Manual. The

warranty is valid for continental United States, Hawaii, Alaska, Canada and Mexico. TurboChef by Blodgett agrees to pay our factory authorized service agent for any labor required to

repair or replace at our option any part which proves to be defective due to defects in material or workmanship during the warranty period. This warranty includes actual mileage not to exceed fifty (50) miles (100 miles round trip) or travel time not to exceed two (2) hours. Mileage or travel time exceeding the limits will not be covered unless previously authorized by factory.

This warranty does not cover any defect due to or resulting from handling, abuse, misuse, or harsh chemical, nor shall it extend to any unit from which the serial number has been removed or altered, or modification s made by unauthorized service personnel or damage by flood, fire or other acts of God.

Adjustments such as calibration to the thermostats, leveling, tightening of fasteners or connections normally associated with the original installation are the responsibility of the dealer or installer and are not covered under the terms of this warranty.

Proper installation is the responsibility of the dealer, the owner-user, or installing contractor, and is not covered by this warranty. Many local codes exist, and it is the responsibility of the owner and

installer to comply with these codes. CONSUMABLE ACCESSORIES EXCLUDED. Components and parts that are normally consumed in

the usual course of operation are excluded from this Limited Warranty. Such accessories include, but are not limited to, ceramic platters, air filters, paddles, carts, etc. In addition, Equipment damage resulting from improper care or replacement of such accessories is not covered under this Limited Warranty.

The foregoing is exclusive and in lieu of all other warranties, whether written, oral, or implied, including any warranty of performance, merchantability, or fitness for any particular purpose, and supersedes and excludes any oral warranties or representations, or written warranties or representations, not expressly

designated in writing as a “warranty” or “guarantee” of Turbochef by Blodgett made or implied in any manual, literature, advertising brochure or other materials. This warranty gives your specific legal rights, and you may have other rights which vary from state to state.

In no event shall TurboChef by Blodgett be liable, directly or indirectly, for special consequential or incidental damages, including but not limited to (I) any loss of business or profits, and (ii) labor, materials or other charges, claims, losses or damages incurred or suffered from, in connection with or in circumstances of the working upon, alteration, or repair of any such defective products or parts by persons or firms other than that of TurboChef by Blodgett.

TurboChef Technologies Inc.

10500 Metric Drive Suite 128, Dallas Texas 75243

Telephone (214) 341-9471 FAX (214) 340-8477

Blodgett Advanced Cooking Technologies

290 Boyer Circle, P.O. Box 1440, W illiston, Vermont 05495-1440

Telephone (802) 860-4598, (888) 992-6624 FAX (802) 860-3784

Page 83 of 87

SECTION 13 TECHNICAL APPENDIX

DTR

13.1 APPENDIX A – OVEN CONNECTION TO COMPUTER

13.1.1 Interconnect between oven and modem

Oven Conn.

DB9 Female

1 2 3 4 5 6 7 8 9

(Appendix 1)

DTR

SIG GND

DSR

TX DATA RX DATA

DSR

SIG GND

Modem Conn

DB25 Female

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Oven Conn.

DB9 Female

(Appendix 2)

13.1.2 DIrect interconnect between oven and pc

1 2 3 4 5 6 7 8 9

Data Format: RS 232, 1 Start Bit, 8 Data Bits, 1 Stop Bit, 19,200 Baud.

TX DATA RX DATA

DTR

SIG GND

DSR

Modem Conn

DB25 Female

1 2 3

4 5

6 7 8 9

Page 84 of 87

13.2 APPENDIX B – JAPANESE INPUT POWER FREQUENCY CONVERSION

CAUTION: When installing this oven, make sure that the oven is set up for the correct frequency or damage to the oven may result.

This oven can be made to operate at either 50 or 60 Hz by following these instructions.

1. Make sure that the power cord is disconnected from the source.

2. Remove the oven top cover and right side cover.

3. Locate the two magnetron transformers and the 50 and 60 Hz taps as shown.

WARNING: Ensure that the unit is disconnected from power and capacitors are discharged.

4. Check/Move the high voltage anode wire to the desired 50 or 60 Hz tap on each transformer. For the Japanese oven, the capacitor remains the same,

1.2 µF, for 50 or 60 Hz.

5. Reinstall the right side cover and oven top cover.

200VA

7 (50Hz)

6 (60Hz)

3 4 (NOT USED)

HIGH VOLTAGE MAGNETRON TRANSFORMERS, T1 AND T2

(Conversion)

Page 85 of 87

13.3 APPENDIX C – JAPANESE ADDITIONAL EMI FILTER

78(8X)

(8X)

(2X)

RIGHT SIDE VIEW

(6X)5

ITEM PART NO. DESCRIPTION

1 MBS-1340-33 FILTER, EMI 2 T7001249 BRACKET, JAPANESE SERIES EMI FILTER 3 T7001272 COVER, EMI FILTER 4 T101450 SCREW, #10-32, PPHD, CRES 5 T102260 WASHER, EXT TOOTH LOCK 6 T101665 SCREW, #8-32, PPHD, CRES 7 T102275 WASHER, EXT TOOTH LOCK 8 ACORN NUT, ¼-20, NYLON

2 3

4 (2X)

(EMI Filter - Jap))

Page 86 of 87

13.4 APPENDIX D – T3 & T4 FILAMENT TRANSFORMER 200-208 VOLTAGE SELECTION

CAUTION HIGH VOLTAGE: Disconnect power and ensure capacitors are discharged before working on unit.

To change or confirm the wiring of the filament transformers:

1. Check incoming power to Turbochef unit for 200-208 or 240 VAC power.

2. Refer to diagram A for location of filament transformers. Refer to diagram B

to locate the terminals on the transformers.

3. Verify proper wire location and change if necessary to match facility supply

voltage. a) Terminal #1 is the L1 power supply for wires 201 and 203. b) Terminal #2 is the 200-208 VAC for wires 202 and 204. c) Terminal #3 is the 240 VAC for wire 202 and 204.

NOTE: For accessibility to right filament transformer T4 remove the magnetron cooling fan assembly. Remove the two screws located under the unit that holds the fan assembly in place and disconnect the electrical connections to move fan assembly out of the way.

NOTE: For Japanese units (200VAC supply) use terminal #2.

Old Style

(Units with S/N before 080399IO102S)

WIRE ROUTING: From FL4 terminal 3 to T3 terminal 1 wire 201. From T3 terminal 1 piggyback to T4 terminal 1 wire 203.

DIAGRAM A

DIAGRAM B

New Style

(Units with S/N after 080399IO102S)

WIRE ROUTING: From FL4 terminal 4 to T3

200-208VAC

240VAC

terminal 2 or 3 wire 202. From T3 terminal 2 or 3 piggyback to T4 terminal 2 or 3 wire 204.

(fil trans)

Page 87 of 87

TurboChef l D3 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual