TurboChef l D3 Service Manual
Service Manual
for
TurboChef Model D3 Ovens
See Inside for Important
Steps before Operating Oven.
Customer Service Toll Free Number (888) 992-6624
Copyright July 1, 1999
Blodgett Advanced Cooking Technologies® Inc., All Rights Reserved
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
Page 4 of 87
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
Page 5 of 87
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
Page 6 of 87
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.
Page 7 of 87
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.
Page 8 of 87
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.
$,5),/7(5
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
*5($6(3$1
Page 9 of 87
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
Page 10 of 87
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.
Page 11 of 87
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.
Page 12 of 87
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".
Page 13 of 87
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.
Page 14 of 87
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.
Page 15 of 87
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.
Page 16 of 87
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
Pin
'
(
)
*
CCC
EC
,
.
/
IAF ABC1
JKL4
0
/+%41
••
••
••
••
••
SN DEF2
FF MNO5
2
/+%41
#+4
°C/°F
9
10
11 Heat Exchanger
12 Magnetron 1 Temperature OK
13 Magnetron 2 Temperature OK
MS GH13
PQR6
4
#+4
'&+6
*'#6
%11.
&190
5612
9#4/
72
-'4
4'57/'
3DQHO
Filter Door Monitor 6
Blower Running 7
When light is on, item is active.
••
••
8
••
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
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
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