TurboChef NGC General Manual

TurboChef Service Manual

( )

Accelerating the World of Cooking

800.90TURBO

Part Number: NGC-1007 / Revision A, July 23, 2004

IMPORTANT SAFET Y INFORMATION - PLEASE READ FIRST

: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operating and maintenance instructions thoroughly

before installing or servicing this equipment.

This product employs an exposed radiant heating element on the bottom of the cavity. This element is HOT during operation and will remain at dangerous temperatures after the unit is switched off. NEVER attempt to touch the element during operation or while the oven is warm.

οx store or use gasoline or any other flammable vapors or liquids in the vicinity of this or any other appliance.

The information contained in this manual is important for the proper installation, use and maintenance of this oven. Adherence to these procedures and instructions will result in satisfactory baking results and long trouble-free service. Please read this manual carefully and retain it for future reference.

Errors - descriptive, typographic or pictorial - are subject to correction. Specifications are subject to change without notice.

Table of Contents

Important Safety Instructions	i
Precautions to Avoid Possible Exposure to Excessive Microwave Energy	ii
Grounding Instructions	ii
RF Interference Considerations	ii
Chapter 1: Installation, Specifications and Maintenance
Specs and Dimensions	1
Dimensions
Construction
Standard Features
Accessories
Certification
Packaging
Power Supply - North America
Delivery and Product Placement	2
Lifting and Placement of the Oven
Restraint Oven Kit
Electrical Specifications	2
Setup and Initial Operation	2
Setup
Programming
Initial Power-Up
Maintenance	3
Chapter 2: Theory of Operation
The Theory of Operation	5
Glossary of Common Operating Terms	6
Chapter 3: Fault Codes
To View Fault Codes	9
Fault Code Definitions	9
Fault Code Table	10
Chapter 4: The Control System
Control System Schematic	11
Control System Component Descriptions	12
Test Function Options	13
Status Indicators	14
Programming	14
User Configurable Options	15
Passwords	16
Control System Panel Parts	17
Control System Trouble Shooting	18

Chapter 5: The Microwave System
Overview of a Microwave Circuit	21
Monitor Circuit Description	21
Microwave Circuit Theory of Operation	22
Microwave System Parts	22
Microwave System Components	23
Wave Guide Cover Replacement	24
Wave Guide/Wave Guide Cover Parts	25
Wave Guide Replacement and Cleaning	26
High Voltage Transformer & Filament Transformer Replacement	26
Wiring the High Voltage Transformers
Wiring the Filament Transformers
Measuring RF Leakage for Microwave Safety	27
Testing Microwave Components	28
Testing the High Voltage Diode
Checking a Diode
Checking a Capacitor
Checking a Magnetron for Open/Shared Filament
Checking a High Voltage Transformer or Filament Transformer
High Voltage and Filament Transformer Resistance Table	29
Microwave System Trouble Shooting	30
Chapter 6: The Cook Door
Removing/Reinstalling the Cook Door	33
Cook Door Parts	33
Adjusting the Cook Door	34
Adjusting the Primary and Secondary Interlock Switches	34
Primary and Secondary Interlock Switches Adjustments and Parts	35
Door Switch Assembly and Parts	36
Adjusting the Monitor Safety Switch	36
Monitor Safety Switch Parts	37
Cook Door Assembly	38
Cook Door Parts	38
Screw Torque Chart	39
Interlocks Trouble Shooting	40
Chapter 7: The Convection Circuit
Convection System Components	41
Convection Circuit Parts	42
Blower Motor Parts	43
Convection Circuit Trouble Shooting	44
Motor Winding Resistance Table	45

Chapter 8: IR Element and Catalytic Converter
Components	47
IR Element and Catalyst Removal	47
Removing the IR Element
Removing & Installing the Catalytic Converter
Installing a New IR Element
IR Element and Catalytic Converter Parts	48
Chapter 9: Schematic and Schematic Parts
NGC (Tornado) Schematic	Inside 49
Schematic Parts	49
Line Voltage Components
Low Voltage Components
Wire Harness Replacement P/N’s
I/O Control Board Item Identification and Test Point Locations	49
Chapter 10: Service Parts and Illustrations
Figure 4: NGC (Tornado) Control System	51
Figure 12: Control System Panel Enclosure and Parts	52
Figure 13: Monitor Circuit - Shown in Failsafe State	53
Figure 15: Microwave System Parts	53
Figure 16: Microwave System Parts	54
Figure 17: Wave Guide Cover/Wave Guide Removal and Replacement	54
Figure 18 & 19: High Voltage Transformer and Filament Wirings	55
Figure 21&22: High Voltage Diode and Magnetron	55
Figure 23: Cook Door Removal and Parts	56
Figure 26: Primary and Secondary Interlocks Adjustment and Parts	56
Figure 27: Door Switch Assembly and Parts	57
Figure 28: Motor Switch Adjustment and Assembly	58
Figure 29: Cook Door Assembly	59
Figure 31: Convection Circuit Block Diagram	60
Figure 32: Convection Circuit Assembly and Parts	61
Figure 33: Blower Motor Parts and Assembly	62
Figure 34: IR Element and Catalytic Converter Parts and Assembly	63
Figure 35: NGC (Tornado) Schematic	64
Figure 36: I/O Control Board and Test Point Locations	64
Figure 37: Covers and Miscellaneous Parts	66

I N T R O D U C T I O N i

I M P O R TANT SAFET Y INSTRUCTIONS

The following basic safety precautions should be strictly adhered to when using electrical appliances, so as to reduce the risk of burns, electric shock, fire, injury to persons or exposure to excessive microwave energy.

οRead all instructions before using the appliance.

οRead and follow the Specific Precautions to Avoid Possible Exposure to Excessive Microwave Energy found on page ii.

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

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

οSome products such as whole eggs and sealed containers - for example: closed glass jars - may explode and should not be heated in this oven.

οUse this appliance only for its intended use as described in this manual.

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

οKeep cord away from heated surfaces.

οx allow children to use this appliance.

οx 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.

οx operate this appliance if it has a damaged cord or plug, is not working properly, or has been damaged or dropped. See Power Supply Cord Replacement found on page ii.

οx cover or block any openings on the appliance. οx store this appliance outdoors.

οx use this product near water - for example: near a kitchen sink, in a wet basement or near a swimming pool.

οx immerse cord or plug in water.

οx let cord hang over edge of table or counter.

οx use a water jet for cleaning. See the Maintenance section of this manual on page 3 for proper cleaning procedures.

To reduce the risk of fire in the oven cavity:

οRemove wire twist-ties from paper or plastic bag in the oven.

οIf materials inside the oven should ignite, keep oven door closed, turn oven off and disconnect the power cord or shut off power at the fuse or circuit breaker panel.

οIf smoke is observed, switch off or unplug the oven. Keep the door closed in order to stifle any flames.

οx use the cavity for storage purposes.

οx overcook food. Carefully attend the oven if paper, plastic or other combustible materials are placed inside the oven to facilitate cooking.

οx leave paper products, cooking utensils or food in the cavity when not in use.

SAVE THE SE INSTRUCTIONS

ii I N T R O D U C T I O N

P R E CAUTIONS TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY

To reduce the risk of exposure to excessive microwave energy:

οx attempt to operate this oven with the door open. Open-door operations can result in harmful exposure to microwave energy. It is important not to defeat or tamper with the safety interlocks.

οx place any object between the oven front face and the door or allow soil or cleaner residue to accumulate on the sealing surfaces.

οx operate the oven if it is damaged. It is particularly important that the oven door close properly and that there is no damage to the door (bent), hinges and latches (broken or loosened), door seals and sealing surfaces.

οx have the oven adjusted or repaired by anyone except a factory authorized service technician.

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 that has a grounding wire with a grounding plug. The plug must be plugged into an outlet that is properly installed and grounded. Consult a qualified electrician or serviceman if uncertain about the ability to follow grounding instructions or if doubt exists as to whether the appliance is properly grounded.

οx 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, its service agent or a similarly qualified person in order to avoid a hazard.

: Improper grounding can result in a risk of electric shock.

RF INTERFACE CONSIDERATIONS

The NGC (Tornado) oven generates radio frequency signals. This device has been tested and was determined to be in compliance with applicable portions of FCC part 18 requirements and to the protection requirements of Council Directive 89/336/EEC on the approximation of the laws of the Member States relating to electromagnetic compatibility at the time of manufacture. However, some equipment with sensitivity to signals below these limits may experience interference.

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

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

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

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

οKeep sensitive equipment on separate electrical circuits if possible.

οx route intercom wires, microphone wires or speaker cables near the oven.

SAVE THE SE INSTRUCTIONS

INSTALLATION, SPECIFICATIONS AND MAINTENANCE

1

: NGC (Tornado) Dimensions

SPECS AND DIMENSIONS
Dimensions
Height	23” (with 4” legs)	8”
Width	26”	15.5”
Depth	25.7”	14.7”
	28.2” (with handle)
Weight	190 lbs.

Back 0” Sides 2”

(minimum) Crated 30”

Uncrated 24”

Construction

ο430 stainless steel front, top and sides.

ο4” chrome plated adjustable legs

οNickel plated handle

οCool to the touch pull down door

ο304 stainless steel line

οFully insulated cooking chamber

οRemovable wire cooking rack with optional platter

οAdjustable lower cooking element

Standard Features

οRecirculating airpath with TurboChef Technologies patented catalytic converter system

οMulti-speed convection blower

οConventional wire baking rack

οIndependently controlled bottom browning element

οStackable design

οSmart Voltage Sensor Technology

οFactory programmed with up to 128 cooking programs

οSmart Card for remote programming

οWarranty - 1 year parts and labor

Accessories (Additional Charge)

ο24” stainless steel oven stand with locking casters for single units

ο17” stainless steel oven stand with locking casters for stacked units

Certifications

UL, cUL, NSF, FDA, FCC

Packaging

All ovens are packaged in a double-wall corrugated box with integrated corrugated skids.

2 INSTALLATION, SPECIFICATIONS AND MAINTENANCE

Power Supply - North America

Universal Voltage:	208/240 VAC, 60 Hz,
	1 phase
Amperage:	Nameplate rating 30 Amp
	(3-wire including ground)
Cordset:	10 gauge, 3 conductor,
	5 foot cordset
Plug:	NEMA 6-30

: The Smart Voltage Sensor Technology does not compensate for lack of or over voltage situations. It is the responsibility of the owner to supply voltage to the unit according to the above specifications.

DELIVERY AND PRODUCT PLACEMENT

Remove oven from carton. Immediately note any damage and contact shipping company within 24 hours in order to file a claim. TurboChef will not be responsible for product damaged in shipment. The carton may be discarded after oven is removed.

: Oven weight is approx. 190 lbs. Two or more persons are required to lift it.

Lifting and Placement of the Oven

Position one or more persons on either side of the oven and lift from the bottom. Never lift the oven from the front and rear. Place the oven on a countertop surface at least 28 inches deep and capable of supporting 200 lbs.

Once properly positioned on the counter, plug the oven into a NEMA 6-30R wall mounted electrical receptacle. See Electrical Specifications.

Restraint Oven Kit (P/N TC3-0240)

An optional system intended to hinder the oven from moving forward during use and/or cleaning. The Restraint Oven Kit will not prevent the oven from falling off a countertop if the legs are allowed to slide off the edge or if the oven is intentionally or forcefully pulled off.

Proper installation instructions are included in the Restraint Oven Kit, if the operator has ordered one. If additional help is needed, please call customer service at 800.90TURBO.

ELECTRICAL SPECIFICATIONS

Operating Voltage	208 VAC/240VAC
Current Draw	30 Amps
Phase	1 Phase
Frequency	60 Hz
Max Input	5990/6675 watts
Microwave Input Power	3500 watts*

*Maximum Independent Input Power

: Never lift the oven by its door handle. Physical damage to the oven and/or

personal injury may result. The operator must ensure that the oven is properly placed on the countertop at all times. TurboChef will not recognize a fallen oven as a warrantable claim and is not liable for any injuries that may result.

SETUP AND INITIAL OPERATION

Setup

Once oven is properly positioned on the counter, remove any packing material and/or any foreign objects from within the cavity. Install the oven rack by sliding the rack onto the support shelves.

Programming

The oven comes preprogrammed and is ready to operate out-of-the-box.

Initial Power-up

To turn the oven On, press the “On” Key next to the word “On” on the display. The oven will begin to warm up to its predefined cooking temperature of 500ºF. This takes approximately 10 minutes.

When the Warm-up Cycle is completed, the oven will beep and display the “Ready State”. At this point, the oven is ready to cook.

INSTALLATION, SPECIFICATIONS AND MAINTENANCE

3

1

2

6

7

DAILY MAINTENANCE FOR THE NGC

The Daily Cleaning Recommendation below will help in maintaining the NGC (Tornado) oven. Be sure to use only TurboChef® Oven Cleaner. The use of any other cleaning products can damage critical parts and may void warranty on those parts.

Supplies and Equipment

TurboChef® Oven Cleaner, nylon green scrub pad, cleaning towel

Step 1: Prepare the Oven.

οTurn oven off by pressing the “Back” key.

οThe oven will display “Oven Off-Cooling Down”. οx attempt to clean oven during the cool

down cycle, indicated by “Cooling Down” signal on display.

οCooling takes approximately 90 minutes.

: The oven operates at 500ºF and may cause injury if not allowed to cool properly.

Step 2: Remove the Lower Access Panel.

ο Wipe out any crumbs that have collected.

Step 3: Remove the Wire Rack.

ο Wash, rinse and sanitize the wire rack.

: Be sure oven interior is cool prior to removing the wire rack.

3

4

5

8

9

10

Step 4: Lift Bottom Element.

ο Be sure the bottom element is cool prior to lifting.

: The oven element operates at 1000ºF and may cause injury if not allowed to cool properly.

Step 5: Remove Particles and Spray Oven Interior with TurboChef® Oven Cleaner.

οUsing a damp towel, remove any large particles from the oven.

οIf stubborn stain is present, sparingly spray TurboChef ® Oven Cleaner into the cavity and on the door.

οAllow cleaner to penetrate for five (5) minutes.

οNever saturate the bottom of the oven with water or oven cleaner.

Step 6: Clean Oven Interior.

οUsing a nylon green scrub pad, clean the oven door and cavity.

: Do not apply pressure to white Wave Guide Caps. Breaking will result in a

non-warranty service call.

Step 7: Wipe Out Oven Interior.

οWipe oven door and cavity clean using a damp towel.

οWipe the element with a clean damp towel.

4 INSTALLATION, SPECIFICATIONS AND MAINTENANCE

Step 8: Clean Area where Lower Access Panel is Located.

οWipe the area on the outside of the oven where the lower access panel is located.

οx spray any chemical in this area.

Step 9: Lower the Bottom Element and Replace the Wire Rack and Lower Access Panel.

Step 10: Clean Oven Exterior.

οWipe the oven exterior with a clean, damp towel.

οOven is ready to turn on.

D O ’S AND DO NOT ’S

DO:

οEnsure the oven is cleaned daily.

οUse only TurboChef® Oven Cleaner.

οRemove items from the oven as soon as they are cooked.

οUse only microwave-safe TurboChef approved cooking accessories in the oven.

οReview cooking instructions to ensure oven settings are correct for corresponding products.

οKeep the TurboChef Installation Guide for future reference.

οCall TurboChef immediately if Wave Guide Caps are broken.

DO NO T:

οx Lift oven by handle.

οx Slam or mishandle the oven door.

οx Place foil or metal objects of any kind in the oven. οx Operate the oven without food in the cook

chamber.

οx Frequently open and close the door to check the product.

οx Cook items wrapped in plastic or any type of cling film.

οx Put products in the oven until ready to cook. οx Use cleaning agents that are not approved for

the oven.

οx Allow any cleaning solution or water to remain on the bottom of the cooking chamber after cleaning or at any other time.

οx Place excessive weight on top of the oven.

THE THE ORY OF OPERATION

The TurboChef NGC (Tornado) oven utilizes three independent heat transfer mechanisms in order to rapidly cook food.

The systems are as follows:

οConvection

οInfrared energy

οMicrowave energy

By combining these mechanisms along with the ability to control each mechanism independently, the NGC (Tornado) oven is able to reduce the cook time of most foods by 70-90 percent.

THEORY OF OPERATION

5

Figure 2 below represents the oven’s different systems and the critical components of each system. Should a problem arise with any of the components listed below, please turn to the appropriate section within this manual for further instructions.

For the purpose of this manual, each independent heat transfer mechanism is individually identified. For instance, if an oven is experiencing difficulties browning the food, focus on the Convection Circuit and/or the Infrared Circuit, versus the Microwave Circuit. Focus on the Microwave System if an oven is browning the food but not heating the food.

Chapter 4	Chapter 5	Chapter 7	Chapter 8
CONTROL SYSTEM	MICROWAVE SYSTEM	CONVECTION SYSTEM	BOTTOM IR AND CCV
I/O Control Board	Magnetrons	Convection Heater	Bottom Infrared Element
Keypad	High Voltage Transformers	Blower Controller	Mechanical Relays
Display	Filament Transformers	Convection Blower	SS Relays
Mechanical Relays	High Voltage Capacitors	Catalytic Converter
SS Relays	High Voltage Diodes	Hi-Limit Thermostat
	Fuse

: NGC (Tornado) Systems and Critical Components

6 THEORY OF OPERATION

G LOSSARY OF COMMON OPERATING TERMS

Off State

All the oven’s control systems are off and the Cook Chamber Temperature is below 150ºF.

Cool Down

A subset of the Off State. During Cool Down the oven will circulate the main convection blower until the Cook Chamber Temperature is below 150ºF.

Ready State

Refers to an oven that has successfully warmed-up to the predefined Set-Temperature. At this point the oven control is ready to receive cook commands via the Keypad.

Set-Temperature (TSET)

A predefined temperature at which the oven cooks.

Cook Chamber Temperature (TCC)

The actual temperature registered by the Cook Chamber Thermocouple.

Edit Mode

The mode which enables the user to change stored or predefined Recipes and the Set-Temperature.

Warm-Up

The mode when the oven is warming itself to the Set-Temperature.

Idle Mode

Similar to the Ready State. In this mode, the oven’s control may cycle the blower or heaters in order to maintain the Set-Temperature.

Cook Cycle

A period of operation as defined by a Recipe.

Test Mode

A special diagnostic mode that enables the service technician to turn on and off all oven systems independent of one another.

Keypad

The primary interface for the operator.

Display

Displays all visual information to the operator.

Self-Test (STEST)

A special diagnostic function that tests all critical subsystems to determine their operational state.

Recipe

A set of user defined Events that determine a Cook Cycle.

THEORY OF OPERATION

7

Events

A single operational element that is a part of a Recipe. Each Recipe may have up to six Events depending on programming. Each Event lasts a percentage of the Total Cook Time and can be set between 0 and 100% of the Total Cook Time. The sum of all the Event Percent (%) Times must equal 100%.

Total Cook Time

The total duration of a Recipe.

Percentage (%) Time

An event subset that specifies the duration of the Event.

Percentage (%) Air

An event subset that specifies the relative amount of impingement airflow (speed of convection motor) during the Event. Valid between 10 and 100%.

: Maximum 100% = 7100 RPM Blower Motor Speed. Blower Motor Speed scale is linear.

Percentage (%) Microwave (MW)

An event subset specifying the microwave cycle (on time) during the Event. Valid between 0 and 100%.

Fault Code

A code assigned to an Event that the Control considers to be a failure. Upon discovering a Fault, the Control will display the Fault Code and a brief description of the failure. The Control will also increment the Fault Code Counter.

Error Message

A message that is displayed when an unusual event occurs. The Control will display the Error Message only when it occurs. Error Messages are not logged in the Fault Code Counter.

The NGC (Tornado) oven has the ability to continually monitor and log various fault conditions. Some fault conditions will terminate Cook Cycles, while others will not. Please refer to the Fault Code Table on page 10 for more detailed information.

When a fault is detected, the Fault Code Counter will increment. However, if the fault is subsequently cleared by some action, whether service related or not, the Fault Code Counter will not decrement.

TO VIEW FAULT CODES

To view the Fault Log, press the “4” and “6” Keys simultaneously while the oven is in the Off State. The oven will display all faults logged. Figure 3.

Each Fault Log will log up 255 instances before rolling back to zero. Press the “0” Key to reset the Fault Code Counter.

: The Fault Log also displays the Cook Counter, which will log up to 65,535 Cook Cycles. In order for the Control to log a Cook Cycle, the oven must complete the first Event of any given Recipe. If a Recipe only has one (1) Event, the oven must complete the entire Cook Cycle in order to count the Cook Cycle.

FA ULT CODE DEFINITIONS

F1: Blower Running Status Bad

Fault is displayed when the Blower Controller indicates no running status.

The Motor and Motor Controller state is monitored continuously in all Modes with special handling in the Self-Test and Test Mode. If a fault is detected, the Control will bounce the oven into the Off State. Upon turning the oven On, the Control will attempt to restart the Motor. If the restart is successful the fault indication will be cleared. The fault is also cleared at the onset of cooking or when the blower is tested in the Test Mode.

FAULT CODES

9

NGCVXXXX XXXXXX

S/N XXXXXX

COOK COUNT	0
F1 BLOWER	0
F2 LOW TEMP	0
F3 MAG CURR	0
F4 MONITOR	0
F5 MAG TEMP	0
F6 TEMP	0

: Fault Display

F2: Cook Temperature Low

Fault is displayed if the Cook Chamber Temperature is more than 84ºF below the Set Temperature after five (5) seconds into a Cook Cycle.

The fault is cleared at the onset of cooking if the Cook Chamber Temperature is within 84ºF of the Set Temperature or when the heater is tested in the Test Mode.

F3: Magnetron Current Low

Fault is displayed when the Current Transformer (CT) on the I/O Control Board does not detect enough current. The Fault is monitored when the microwave is on during a Cook Cycle or Self-Test.

The fault is cleared at the onset of a Cook Cycle if the CT detects current or when the magnetron is successfully energized in the Test Mode.

F4: Door Monitor Defective

Fault is displayed when the Control detects that the Monitor Interlock Switch unlatches before both the Primary and Secondary Interlock Switches during a Cook Cycle.

In addition this fault will blow the F3 Fuse if the microwave high voltage system is energized when the fault occurs. The fault is cleared only when the oven is turned Off and On.

10 FAULT CODES

: Door Interlock Switches are in parallel. See Figure 35, on the inside of page 49. The fault is monitored during a Cook Cycle or Self-Test, when the Microwave is on.

F5: Magnetron Over Temperature

Fault is displayed when the Thermostat on either Magnetron is “Open”.

The fault is cleared at the onset of a Cook Cycle if the Thermostat is closed or when the Magnetron is successfully tested in the Test Mode.

F6: EC (Electrical Compartment) Temperature High

Fault is displayed when the EC Thermocouple exceeds 158ºF and is monitored once per minute.

The fault is cleared when the EC Thermocouples temperature is below the indicated limit.

FAULT CODE TABLE

F7: Thermocouple Open

Fault is displayed when the Control detects that either the IR or CC Thermocouple is “Open”.

ο999ºF indicates the CC Thermocouple is “Open”.

ο1999ºF indicates the IR Thermocouple is “Open”.

Fault is cleared when the control detects continuity on the open Thermocouple Circuit.

F8: Heat Low

An Error Message (not a Fault Code) displayed during Warm-up or Self-Test if the Cook Chamber Temperature (TCC) fails to rise 14ºF within thirty (30) seconds.

FAULT CODE AND DESCRIPTION	WHEN ACTIVE				REFER TO
	Warm - up	Idle Mode	Cook Mode	Self-Test
F1: Blower Running Status Bad	X	X	X	X	Page 19
F2: Cook Temperature Low			X		Page 20
F3: Magnetron Current Low			X	X	Page 30
F4: Door Monitor Defective			X		Page 36
F5: Magnetron Over Temperature			X	X	Page 24
F6: EC Temperature High	X	X	X		Page 12
F7: Thermocouple Open	X	X	X	X	Page 18
F8: Heat Low	X			X	Page 44

Fault Codes are listed in order of hierarchy. For example: If during cooking the oven experiences an F1 and F2 Fault, the oven will only report a F1 Fault since the software will halt all actions upon discovering the F1 Fault. F7 and F8 Faults are displayed on the primary screen and are not displayed or counted in the Fault Log.

: All Fault Codes listed in Bold will terminate a Cook Cycle upon discovery. Any fault occurring in a Cook Cycle will be logged in the Fault Code Counter.

THE CONTROL SYSTEM

11

The Control System is comprised of the components that signal, sense, command and switch the oven’s various components. Figure 4 shows a functional diagram of all the components that make up the Control System.

: The part numbers for each component are given within the parentheses in addition to being included with the descriptions for each part on the following page.

			+24 VDC
							K5			K4
	K1	K2	K3	K6
								DUAL
	MECH	MECH	MECH	MECH
								SSR
	RELAY	RELAY	RELAY	RELAY
								RELAY
	(101271)	(101271)	(101271)	(101272)
								(101284)
	+ 24 VDC -	+ 24 VDC -	+ 24 VDC -	+ 24 VDC -			3(+)	4(-)		3(+) 4(-)

L

+V

+24 VDC

24 VDC

N POWER SUPPLY

-V

MONITOR SWITCH

+24 VDC

(101206)

NC

C

NO

(102012)

MONITOR

INTERLOCK

COMMON

BMSC

+24 VDC

(100443)

1

0-10V

1

CONVECTION HEATER COMMAND

2

200-240

SPD

IR ELEMENT COMMAND

3

VAC IN

CMD

I/O COM

2

ENABLE

3

1

240 VAC

I/O COM

4

I/O

PRIMARY SWITCH

PRIMARY SWITCH

2

STATUE OK

5

NC

C

3 PHASE

INTERLOCK

3

OUT

I/O COM

6

CONTROL

NO

(102012)

4

BOARD

SECONDARY SWITCH

SECONDARY SWITCH

(NGC-1008)

NC

C

INTERLOCK

NO

(102012)

VOLT

VOLTAGE INPUT

COMMON

COMMON

(100783)

A(-)

<![if ! IE]> <![endif]>12

<![if ! IE]> <![endif]>12

<![if ! IE]> <![endif]>12

<![if ! IE]> <![endif]>12

IR THERMOCUOPLE

C(+)

VDF

A(-)

DISPLAY

(100505)

EC THERMOCUOPLE

C(+)

<![if ! IE]> <![endif]>26 25

<![if ! IE]> <![endif]>26 25

<![if ! IE]> <![endif]>26 25

<![if ! IE]> <![endif]>26 25

A(-)

CC THERMOCUOPLE

C(+)

12

14

12

14

12

14

12

14

KEYPAD

(NGC-1110)

: NGC (Tornado) Control System

12 THE CONTROL SYSTEM

CONTROL SYSTEM COMPONENT DESCRIPTIONS

24 VDC Power Supply (P/N 101206)

24 VDC Output at 40 Watts. Supplies control voltage for I/O Control Board, 24 VDC Mechanical Relays and Solid State Relays.

K1 Mechanical Relay (P/N 101271)

240 VAC, 30 Amp, Double Pole, Double Throw, 24 VDC Relay Coil. Switches power to the Magnetron Filament Transformers.

K2 Mechanical Relay (P/N 101271)

240 VAC, 30 Amp, Double Pole, Double Throw, 24 VDC Relay Coil. Switches power to the Magnetron High Voltage Transformers.

K3 Mechanical Relay (P/N 101271)

240 VAC, 30 Amp, Double Pole, Double Throw, 24 VDC Relay Coil. Safety Interlock device designed to short L1 and L2 if the Monitor Switch opens before the Primary and Secondary Interlock Switches.

K4/K5 SSR (P/N 101284)

240 VAC, Dual 40 Amp Solid State Relay. K4 (right) controls the Convection Heater and K5 (left) controls the IR Element.

K6 Mechanical Relay (P/N 101272)

240 VAC, 30 Amp, Three Pole, Double Throw, 24 VDC Relay Coil. Responsible for switching between the 208VAC and 240VAC taps on the High Voltage and Filament Transformers.

Interlock Switches (P/N 102012 for all three)

Primary, Secondary and Monitor Interlock Switches. Switches must be actuated by the Cook Door in the following order: M-S/P. When the Cook Door opens, the order is reversed: P/S-M.

IR Thermocouple (IR Element)

Type K Thermocouple. Thermocouple is embedded in the IR Element. The Thermocouple measures the internal/sheath temperature of the IR Element. Valid IR Set points are between 500ºF and 1200ºF. The display indicates 1999ºF, if the Thermocouple is “Open”.

EC Thermocouple (P/N 700-1179)

Type K Thermocouple. Thermocouple measures the temperature of the Electrical Compartment. If the temperature within the Electrical Compartment is above 158ºF, the Control displays “F6 - EC Temp”.

CC Thermocouple (P/N NGC-1140)

Type K Thermocouple. Thermocouple measures the temperature of the re-circulating impingement airflow. Valid IR Set points are 450-540ºF. If the display indicates 999ºF, the Thermocouple is Open.

BMSC (P/N 100443)

A proprietary Brushless DC Motor Controller designed solely to operate the Convection Motor.

VDF Display (P/N 100505)

Vacuum Fluorescent Display.

Keypad (P/N NGC-1110)

3x8 Matrix Membrane Switch. Keypad is connected to the Control via a 14 Pin Flat Cable.

Voltage Sense Module (P/N 100783)

Proprietary device designed to measure incoming line voltage and switch between 208 and 240 VAC operation. The device only measures and configures the oven when the oven is switched from the Off State to the On State.

TE ST MODE

The Test Mode allows the service technician to operate the oven’s subsystems individually. It also allows the operator to configure various presets.

To enter the Test Mode:

1.Press the “Back” Key until the display is in the Off State.

2.Press the “Back” and “Enter” Key simultaneously.

3.Enter the access code: 9-4-2-8 when prompted and press “Enter”.

The “Test” Screen displays the Software Version, Cook Chamber and IR Element Temperature at the top of the screen. The Control also displays the

THE CONTROL SYSTEM

13

TEST NGC VXXXX

CC 810F	IR 5000F
BLOWER	HEATER
FAULTS	MGTRON
STEST	IR ELE

P S M t h i A W

TEST NGC VXXXX

CC 810F	IR 5000F
DIAG	0ELEC
CCC	F/C
PIN	IR SI

P S M t h i A W

: Test Mode - Screen 1

: Test Mode - Screen 2

first of two (2) pages of the test function options (Figure 5). To display the second page (Figure 6), press either the “Down or Up Arrow” Key. To test a component or sub-system, press the corresponding Soft Key.

T EST FUNCTION OPTIONS

Blower Speed

The “Blower” Key increments the Blower Speed in 10% steps. When the Blower Speed is 100%, the next press sets the speed to 0%.

Electronic Compartment Temperature

The “ºELEC” Key displays the temperature inside the electronic enclosure.

Self-Test Function

The “STEST” Key initiates the Self-Test function to test all major components of the oven. To run the Self-Test, press the corresponding Soft Key once. Press the “Back” Key to return to the Idle Mode.

Heater Test

The “Heater” Key turns the heater On or Off. If the heaters are On, pressing the corresponding Soft Key turns the heaters Off. If the heaters are Off pressing the “Heater” Key turns the heaters On. If the Blower Speed is 0, the Blower Speed is set to the Idle Airflow.

Magnetron

The “MGTRON” Key is a press and hold key to test the Magnetron. If the Magnetron Filaments are Off when the “MAG” Key is pressed, the message “MAG Warming Up” is displayed. After a five (5) second delay or if the filaments are already On, “MAG Power On” is displayed. The Magnetron should operate at this point. Once the “MGTRON” Key is released, the high voltage supply is switched Off to the Magnetron and the Magnetron will stop radiating; however, the power is still supplied to the Magnetron Filaments and Magnetron Cooling Fan for an extra three (3) minutes.

Diagnostic Display

The “DIAG” Key turns On or Off the Diagnostic Display feature. This feature adds temperature displays to the “Menu Group” Screens.

While cooking, the Cook Cycle parameters are displayed when diagnostics are enabled.

In addition, the Status Indicators are displayed on the bottom of the screen. When a Status Indicator is highlighted/backlit the corresponding system associated with that Status Indicator is Off. For example: W would indicate that the Microwave System is Off.

The Status Indicator section on the following page offers a more detailed description of each indicator.

14 THE CONTROL SYSTEM

Faults

Pressing the “Faults” Soft Key will display all the accumulated faults in the Fault Log. For more information, see page 9.

F/C

Changes how the oven’s temperature units are displayed. The F/C Key alternately selects Fahrenheit or Celsius.

CCC

Displays the total number of accumulated Cook Counts for all Recipes.

PIN

Allows the operator to select a new Access Number for entering the Test and Edit Modes.

IR ELE

Pressing the “IR ELE” Key will turn On the IR Element. When pressed, the Control will display “IR Element On”. To turn the IR Element Off, push the “IR ELE” Key an additional time.

IR SI

This is a factory setting and should never be altered. Consult the factory before changing this value.

STATUS INDICATORS

See Figures 5 and 6 on page 13.

P Primary Switch – closed or open S Secondary Switch – closed or open M Monitor Switch – closed or open

t Magnetron Thermostats – closed or open

hMain Convection Heater – off or on

iIR Element – off or on

ABlower Motor Controller – enabled or disabled

WMicrowave Current – Less than or greater than 7 Amps*

*Microwave (MW) Status Indicator is not highlighted/backlit when the current is more than 7 Amps.

The Status Indicators are displayed at the bottom of the display screen when the oven is in the Test and DIAG Mode. Refer to Figures 5 and 6.

If a Status Indicator is highlighted/backlit the item or component is in an un-energized or Off State. Conversely, if a Status Indicator is not highlighted, the component is energized or in the On State.

PROGRAMMING

Edit Mode

The Edit Mode enables the operator to alter Recipes and the Cook Chamber Temperature (TCC).

To access the Edit Mode:

1.Press the “Up and Down Arrow” Keys on the Keypad simultaneously.

2.When prompted, enter the Access Code “9” and then press “Enter”.

Changing the Cook Chamber Temperature

The first screen in Edit Mode allows you to change the Cook Chamber Temperature (TCC) by pressing the “Up and Down Arrow” Keys. The operator may adjust the temperature between 450-540ºF in 10ºF increments. Once you have selected the desired temperature, press the “Enter” Key to set TCC.

Altering a Recipe

The NGC (Tornado) oven control has 128 unique Recipes available for the operator. The display shows two (2) pages each with eight (8) Recipe Groups.

Each Recipe Group contains eight (8) Subgroups or Recipes. See Figures 7 and 8.

To alter a Recipe:

1.Enter the Edit Mode as described earlier.

2.Enter the Access Code “9” and set TCC. The screen displays the first set of eight (8) Recipe Groups. To access the second set of eight (8)

Recipe Groups, press either the “Up or Down Arrow” Key.

THE CONTROL SYSTEM

15

EDIT GROUPS

GROUP A

<

GROUP 1

>

GROUP A

GROUP E

ITEM 1

ITEM 5

ITEM 1

COUNT

0

COOK TIME

00:00

IR SETPT

5000F

GROUP B

GROUP F

ITEM 2

ITEM 6

%TIME

%AIR

%WAV

1

XXX

XXX

XXX

2 XXX

XXX

XXX

3 XXX

XXX

XXX

GROUP C

GROUP G

ITEM 3

ITEM 7

4 XXX

XXX

XXX

5 XXX

XXX

XXX

6 XXX

XXX

XXX

GROUP D

GROUP H

ITEM 4

ITEM 8

TEST

SAVE

: Edit Groups : Edit Groups : Edit Groups

3.Select the Recipe Group which contains the individual Recipe you wish to alter. Select which Recipe you wish to alter by pressing the Soft Key corresponding to the Recipe Item. Figure 8.

4.Use the “Up and Down Arrows” Keys to navigate through a Recipe. Use the Keypad and “Enter” Key to alter any of the following three

(3) parameters: (See Figure 9.)

1.Cook Time

Total duration of the Cook Cycle. Enter the desired time and press “Enter”. Valid times are between one (1) second and five (5) minutes.

2.Infrared Set Point Temperature (IR SETPT) The relative temperature which the lower radiant element will maintain during the entire Cook Cycle. Valid temperatures are between 500ºF and 1150ºF.

3.Events 1…6

Use the Keypad and “Enter” Key to enter values for Percent (%) Time, % Air and % Microwave (MW).

The % Time for all Events must total 100%. The operating system will not allow a combination of Events not totaling 100% or that exceed 100%.

The % Air and % Microwave (MW) parameters are valid between 10 and 100%.

: If an Event is unused, the % Air parameter may default and be displayed as 10%.

Once the desired changes have been made, test the Recipe by pressing the “Test” Soft Key. This will execute the altered Recipe. Once satisfied with the Recipe, press “Save” to permanently store any changes. Press the “Back Arrow” Key four (4) times to exit the Edit Mode.

USER CONFIGURABLE OPTIONS

Users may enable or disable the Edit Mode, Done State and Test State.

Edit Mode

For security purposes the Edit Mode can be disabled.

To disable the Edit Mode:

1.Simultaneously press the “Back Arrow” and “Enter” Keys.

2.Enter the Access Pin: 8-4-3-3 (“T-I-D-E”) and “Enter”.

3.When prompted select “9” to re-enable the Edit Mode or any other Key to disable the Edit Mode.

16 THE CONTROL SYSTEM

	DONE					ENTER COOK TIME
						00:20
	SAVE	COOK				START
	TIME	MORE
: Done State					: Time State

Done State

The Done State (Figure 10) can be removed to eliminate the option to Save an altered Time or the option to Cook More.

To disable the Done State:

1.Simultaneously press the “Back Arrow” and “Enter” Keys.

2.Enter the Access Pin 3-6-6-3 (“D-O-N-E”) and “Enter”.

3.When prompted, press “9” to re-enable or any other Key to disable the Done State.

Time State

This state can be removed in order to prevent the operator from adjusting the Total Cook Time prior to pressing the “Start” Soft Key to begin a Cook Cycle. Figure 11.

To disable the Time State:

1.Simultaneously press the “Back Arrow” and “Enter” Keys.

2.Enter the Access Pin 8-4-6-3 (“T-I-M-E”) and “Enter”.

3.When prompted, press “9” to re-enable or any other Key to disable the Time State.

PASSWORDS

Edit Mode

1.Press “Up and Down Arrow” Keys simultaneously.

2.Enter the Pin “9” and press “Enter”.

Test Mode

1.Press “Back” and “Enter” Keys simultaneously.

2.Enter the Pin “9-4-2-8” & press “Enter”.

Reset Control (Soft Restart)

1.Press “Back” and “Enter” Keys simultaneously.

2.Enter the Pin “9-4-7-1” & “Enter”.

Erase

1.Press “Back” and “Enter” Keys simultaneously.

2.Enter the Pin “3-7-2-7” & press “Enter”.

3.When asked “Erase Menu” press “3”.

: The Erase command permanently deletes all stored Recipes and settings.