WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause property
damage, injury, or death. Thoroughly read the installation, operating, and maintenance instructions
before installing or servicing this equipment.
This product employs an exposed radiant heating element in 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, while the oven is warm, or while the oven is cooling down.
x
o
DO NOT store flammable vapors or liquids (such as gasoline) 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 help
prevent maintenance. 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.
Important Safety Instructionsi
General Safety Informationi
Reducing Fire Riski
Precautions to be Observed Before and During Servicing to Avoid Possible
Exposure to Excessive Microwave Energyii
Grounding Instructionsii
Power Cord Replacementii
RF Interference Considerations ii
Chapter 1: Installation, Specifications and Maintenance
Specs and Dimensions1
Dimensions1
Construction1
Standard Features1
Certifications1
Packaging1
Power Supply (Domestic and Intl Electrical Specifications)1-2
Power Input2
Delivery and Product Placement2
Lifting and Placing the Oven2
Built-In Installation2
Installation Near Open Heat Source3
Oven Restraint Kit4
Ventilation Requirements4
Setup and Initial Operation4
Setup4
Stacking4
Programming4
Initial Power-Up4
Maintenance5
Chapter 2: Theory of Operation
Theory of Operation7
Glossary of Common Operating Terms8
Chapter 3: Fault Codes
To View Fault Codes11
Fault Code Definitions11
Fault Code Table12
Chapter 4: The Control System
Control System Schematic13
Control System Component Descriptions 14
Test Mode14
Test Function Options15
Status Indicators16
Table of Contents
Programming16
Oven Options
User Configurable Options - Enable/Disable Codes
User Configurable Options - Access Codes
18
19
19
Control System Panel Parts20
Control System Troubleshooting
21
Chapter 5: The Microwave System
Voltage Doubler Circuit Description
Monitor Circuit Description
Voltage Doubler Theory of Operation
25
25
26
Microwave System Parts26
Microwave System Components28
Wave Guide Cover Replacement29
Wave Guide/Wave
Guide Cover Parts
30
Wave Guide Replacement30
High Voltage and Filament Transformer Replacement
Wiring the High Voltage Transformers
Wiring the Filament Transformers
Measuring RF Leakage for Microwave Safety
How to Test Microwave Components
Testing the High Voltage Diode
30
30
31
31
32
32
How to Check a Diode32
How to Check a Capacitor33
How to Check a Magnetron for Open/Shorted Filament33
How to Check a High Voltage Transformer or Filament Transformer33
High Voltage and Filament Transformer Resistance Table33
Microwave System Troubleshooting
34
Chapter 6: The Oven Door
Removing/Reinstalling the Oven Door
37
Oven Door Parts37
Adjusting the Oven Door38
Preparing the Oven for Switch Adjustment38
Oven Burn-In Procedure
Adjusting the Primary and Secondary Interlock Switches - Old Switch Setup
Primary and Secondary Interlock Switch Adjustments and Parts
38
38
39
Door Switch Assembly and Parts40
Adjusting the Monitor Safety Switch - Old Switch Setup40
Monitor Safety Switch Parts40
Adjusting the Primary Interlock Switch - New Switch Setup
Primary Switch Adjustment and Parts
42
42
Adjusting the Secondary and Monitor Interlock Switches - New Switch Setup43
Secondary and Monitor Safety Switch Parts43
Oven Door Assembly
Oven Door Parts
Convection Circuit Components47
Convection Circuit/Blower Motor Parts
48
Convection Circuit Troubleshooting49
Motor Winding Resistances Table
50
Chapter 8: IR Element and Catalytic Converter
Components51
IR Element and Catalyst Removal
51
Removing the IR Element51
Removing & Installing the Catalytic Converter
52
Installing a New IR Element52
IR Element and Catalytic Converter Parts52
Chapter 9: Schematics and Schematic Components
Schematic Parts
53
Line Voltage Components53
Low Voltage Components
Wire Harness Replacement P/N’s
I/O Control Board Item Identification and Test Point Locations
Schematic - I/O Board
53
53
53
54
Oven Schematics55 - 63
Chapter 10: Service Parts and Illustrations
Figure 7: NGC (Tornado) Control System65
Figure 17: Control System Panel Enclosure and Parts66
Figure 18: Monitor Circuit - Shown in Failsafe State67
Figure 20: Microwave System Parts67
Figure 21: Microwave System Parts
68
Figure 22: Wave Guide Cover/Wave Guide Removal and Replacement68
Figure 24 & 25: High Voltage Diode and Magnetron
Figure 26: Oven Door Removal and Parts
69
69
Figure 29: Primary and Secondary Adjustment and Parts - Old Switch Setup70
Figure 30: Door Switch Assembly and Parts70
Figure 31: Motor Switch Adjustment and Assembly - Old Switch Setup71
Figure 32: Primary Interlock Adjustment and Parts - New Switch Setup
Figure 33 & 34: Secondary and Monitor Adj. and Assy. - New Switch Setup
Figure 35: Oven Door Assembly
71
72
73
Figure 37: Convection Circuit Block Diagram74
Figure 38: Convection Circuit Assembly and Parts75
Figure 39: IR Element and Catalytic Converter Parts and Assembly76
Figure 46: Covers and Miscellaneous Parts - Non-SBK Ovens
Figure 47: Covers and Miscellaneous Parts - SBK Ovens
77
78
Chapter 11: Comprehensive Part List
Comprehensive Part List
79
INTRODUCTION
IMPORTANT SAFETY INSTRUCTIONS
Strictly adhere to the following safety precautions to reduce the risk of:
o
Burns
o
Electric shock
o
Fire
o
Injury
o
Damage to oven or property near oven
o
Exposure to excessive microwave energy
GENERAL SAFETY INFORMATION
o
Read all instructions before using the appliance.
o
Install or locate this appliance only in accordance with the provided installation instructions.
o
Some products such as whole eggs and sealed containers (e.g., closed glass jars) may explode and should not be
heated in this oven.
o
Use this appliance only for its intended use as described in this manual.
o
This appliance should be serviced only by qualified service personnel. Contact the nearest authorized service
facility for examination, repair, or adjustment.
o
Keep cord away from heated surfaces.
x
o
DO
x
o
DO NOT use corrosive chemicals or vapors in this appliance - it is not designed for industrial or laboratory use.
x
o
DO
or dropped. See
x
o
DO
x
o
DO
x
o
DO
x
o
DO
x
o
DO
x
o
DO NOT use a water jet for cleaning. See the maintenance section of this manual on page 5 for proper cleaning
allow children to use this appliance.
NOT
operate this appliance if it has a damaged cord or plug, is not working properly, or has been damaged
NOT
POWER CORD REPLACEMENT, page ii.
cover or block any openings on the appliance.
NOT
NOT store this appliance outdoors.
NOT use this product near water (e.g., near a kitchen sink, in a wet basement, near a swimming pool).
NOT immerse cord or plug in water.
NOT let cord hang over the edge of table or counter.
procedures.
i
REDUCING FIRE RISK
o
Remove wire twist-ties from paper or plastic bags used to facilitate cooking in the oven.
o
If materials inside the oven ignite,
- Keep oven door closed
- Turn oven off
- Disconnect the power cord or shut off power at the fuse or circuit breaker panel
o
If smoke is observed, switch off or unplug the oven. Keep the door closed to stifle any flames.
x
o
DO NOT use the cook cavity for storage purposes.
x
o
NOT overcook food. Carefully attend the oven if paper, plastic, or other combustible materials are placed
DO
inside the oven to facilitate cooking.
x
o
DO
leave paper products, cooking utensils, or food in the cavity when not in use.
NOT
SAVE THESE INSTRUCTIONS
ii
INTRODUCTION
PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO
EXCESSIVE MICROWAVE ENERGY
NOT operate or allow the oven to be operated with the door open.
DO
(a)
(b) Make the following safety checks on all ovens to be serviced before activating the magnetron or other
microwave source, and make repairs as necessary: (1) interlock operation, (2) proper door closing,
(3) seal and sealing surfaces (arcing, wear, and other damage), (4) damage to or loosening of hinges
and latches, (5) evidence of dropping or abuse.
Before turning on microwave power for any service test or inspection within the microwave
(c)
generating compartments, check the magnetron, wave guide or transmission line, and cavity for
proper alignment, integrity, and connections.
Any defective or misadjusted components in the interlock, monitor, door seal, and microwave
(d)
generation and transmission systems shall be repaired, replaced, or adjusted by procedures described
in this manual before the oven is released to the owner.
A microwave leakage check to verify compliance with the Federal performance standard should be
(e)
performed on each oven prior to release to the owner.
GROUNDING INSTRUCTIONS
This appliance must be grounded. In the event of an electrical short circuit, grounding reduces the risk of
electric shock by providing an escape wire for the electric current. This oven is equipped with a cord
that
has a grounding wire with a grounding plug, which must be plugged into an outlet that is properly installed
and grounded. Consult a qualified electrician or serviceman if uncertain about the ability to follow
ground-
ing instructions or if doubt exists as to whether the appliance is properly grounded.
x
o
DO NOT use an extension cord. If the power cord is too short, have a qualified electrician or service-
man install an outlet near the appliance.
WARNING: Improper grounding can result in risk of electric shock.
POWER CORD REPLACEMENT
If the power cord is damaged, it must be replaced by the manufacturer, its service agent, or a similarly qualified person.
RF INTERFERENCE 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:
o
Increase the physical separation between this oven and the sensitive equipment.
o
If the sensitive device can be grounded, do so following accepted grounding practices.
o
If battery-powered microphones are being affected, ensure that the batteries are fully charged.
o
Keep sensitive equipment on separate electrical circuits if possible.
o
oute intercom wires, microphone wires, speaker cables, etc. away from the oven.
R
Installation, Specifications,
and Maintenance
Standard Features
o
Recirculating airpath with
patented catalytic converter
system
o
Multi-speed convection blower
o
Independently-controlled bottom browning element
o
Stackable design
o
Smart Voltage Sensor Technology (North America only)
o
Factory-programmed, customizable menu settings
o
Smart Card for remote programming
o
Warranty -
1 year parts and labor
Certifications
UL, cUL, NSF, FDA, FCC, TÜV, CE
UL KNLZ Ventless Certification - This product conforms
to the ventilation recommendations set forth by NFPA96
using EPA202 test method.
Packaging
All ovens are packaged in a double-wall corrugated box
banded to a wooden skid.
Power Supply - North America
SMART VOLTAGE SENSOR TECHNOLOGY
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
1
SPECS AND DIMENSIONS
Dimensions
EXTERIORCOOK CAVITY
Height19” (483 mm)8” (203 mm)
with legs23” (584 mm)
Width
26” (660 mm)15.5” (394 mm)
Depth25.7” (653 mm)14.7” (373 mm)
with handle
28.2” (716 mm)
Weight
190 lbs. (86 kg)
WALL
CLEARANCE
Back0” (0 mm) unless built-in (page 2)
Sides
2” (51 mm)
ENTRY CLEARANCE (minimum)
Crated
31.5” (800 mm)
Uncrated
28.7
” (729 mm)
Construction
EXTERIOR
o
430
stainless steel front, top and sides.
o
4
” (102 mm) adjustable legs
o
Cool to the touch handle
INTERIOR
o
304
stainless steel line
o
Fully insulated cooking chamber
o
Removable assorted cooking surfaces
o
Independently-controlled lower cooking element
FIGURE 1: NGC (Tornado) Dimensions
INSTALLATION, SPECIFICATIONS, AND MAINTENANCE
2
INSTALLATION, SPECIFICATIONS, AND MAINTENANCE
NOTE: The Smart Voltage Sensor Technology does
not compensate for lack of voltage or over-voltage
situations.
It is the responsibility of the owner to
supply voltage to the unit according to the following specifications.
Power Supply - Europe, Asia-Pacific
NGC EW (3-phase)
Voltage:
400 VAC, 50 Hz, Wye, 5-
wire (3L + N + Ground)
Circuit Breaker:
Type D, min. 20 Amps
NGC ED (3-phase)
Universal Voltage:230 VAC, 50 Hz, Delta, 4-
wire (3L + Ground)
Circuit Breaker:
Type D, min. 30 Amps
NGC UK (1-phase)
Voltage:
230 VAC, 50 Hz, 3-wire
(2L + Ground)
Circuit Breaker:
Type D, min. 30 Amps
Power Supply - Latin America
NGC BK (1-phase)
Voltage:220 VAC, 60 Hz, 3-wire
(2L + Ground)
Circuit Breaker: Type D, min. 30 Amps
Power Supply - Japan
NGC JD (3-phase)
Voltage:
200 VAC, 50/60 Hz, Delta,
4-wire (3L + Ground)
Circuit Breaker: Type D, min. 30 Amps
NGC JK (1-phase)
Voltage:
200 VAC, 50/60 Hz, 3-wire
(2L + Ground)
Circuit Breaker: Type D, min. 30 Amps
Power Supply - South Korea
NGC KW (3-phase)
Voltage:
400
VAC, 60 Hz, Wye, 5-
wire (3L + N + Ground)
Circuit Breaker: Type D, min. 20 Amps
POWER INPUT
Heaters Input Power (NA) 5990/6675 watts
Heaters Input Power (Intl)
6300 watts
Microwave Input Power 3500 watts*
*Maximum Independent Input Power
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 is not
responsible if the product is damaged in shipment.
Remove all literature and accessories from the carton.
NOTE: Thoroughly check the carton before discarding.
WARNING: Oven weight is approx. 190 lbs.
(86 kg) Two or more persons are required to
lift it.
Lifting and Placing 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 counter
top surface at least 28” (711 mm) deep and capable of
supporting 200 lbs (91 kg).
Once properly positioned on the counter, plug the
oven into wall-mounted electrical receptacle. See
page ii for grounding instructions.
WARNING
: 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.
Built-In Installation (Figure 2)
TurboChef ovens are designed to be installed on a
countertop or table. They are not intended for builtin or enclosed installation.
“Built-in or enclosed installation” is defined as
installing an oven in any structure that surrounds the
oven by five sides (i.e., top/rear/side panels and base).
If installation must be “built in,” the operator must
ensure the following:
o
Minimum of 300 cfm (8.5 cmm) of supplement flow
within the cabinet.
o
Minimum clearances of 2" (51 mm) to every surface.
In addition, the operator will be responsible for compensating any extra time required to service the prod
-
uct due to removing the product for serviceability.
Installation Near Open Heat Source (Figure 3)
When placing a TurboChef oven near an open heat
source, strictly adhere to the following:
o
Verify oven location has a minimum 6" (152 mm)
clearance on top and minimum 2" (51 mm) of
clearance on each side.
o
If the oven is being placed near a grill or stove,
there must be a divider between the oven and the
open heat source, with a minimum of 6" (152 mm)
between the oven and the divider.
o
If the oven is being placed near a fryer, there must
be a divider between the oven and fryer, with a
minimum of 12" (305 mm) between the oven and
the divider.
o
The height of the divider must be greater than or
equal to the height of the oven (23"/584 mm).
FIGURE 2: Built-in Installation Specs
FIGURE
3:
Open Heat Source Installation Specs
INSTALLATION, SPECIFICATIONS, AND MAINTENANCE
3
(102 mm)
4
Oven Restraint Kit (TC3-0242 KIT)
The Oven Restraint Kit is an optional system that
helps prevent the oven from moving forward during
use and/or cleaning. It 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 with the
kit. for additional information, please call customer
service at
800.90TURBO / +1 214.379.6000.
Ventilation Requirements
The TurboChef Tornado
TM
oven has been approved by
Underwriter’s Laboratory for ventless operation (UL
710B, KNLZ listing) for all food items except for foods
classified as “fatty raw proteins.” Such foods include
bone-in, skin-on chicken, raw hamburger meat, raw
bacon, raw sausage, steaks, etc. If cooking these types of
foods, consult local HVAC codes and authorities to
ensure compliance with ventilation requirements.
NOTE: In no event shall the manufacturer assume any
liability for damages or injuries resulting from installations which are not in compliance with the instructions
and codes previously listed.
SETUP AND INITIA L OPERATION
Setup
Once the oven is properly positioned on the counter,
remove any packing material and/or any foreign
objects
from within
the cavity. Install the oven rack/
cooking surface.
Stacking
1. Ensure the surface that will hold the stacked
ovens can support at least 400 lbs (181 kg).
2. Allow ovens adequate time to cool and unplug them
3. If you are stacking ovens on a TurboChef oven
cart (24” = NGC-1217-1, 18” = NGC-1217-2),
make sure that the bottom oven is bolted to the cart
and the wheels are locked.
4. Attach the stacking bracket (P/N TC3-0323) to the
back of the bottom oven:
a. Remove the two screws that hold the top
panel to the back of the oven (see bottom
arrows on Figure 4).
b. Align the holes on the stacking bracket with
the holes on the oven and reinstall the screws.
FIGURE 4: Properly Stacked NGC Ovens
INSTALLATION, SPECIFICATIONS, AND MAINTENANCE
5. Remove the legs of the oven that will be
placed on top. This requires two or more
persons - at least one person to lift and one to
unscrew the legs.
6. Remove the screws from the oven that will be
placed on top (see top arrows on Figure 4).
7. Place this oven on top of the other (the one
to which the stacking bracket is attached).
WARNING: Do not attempt to lift the oven
with fewer than 2 people.
WARNING: Do not lift oven from front
and back.
8. Align the holes on the bracket with the holes
on the top oven and reinstall the screws.
WARNING: Do not stack ovens over two-
high.
Programming
The oven is preprogrammed and ready to operate out of the box.
Initial Power-up
To turn on the oven, press the bottom-right soft
key next to the words
OVEN ON on the display.
The oven will begin to warm up to its predefined cooking temperature. This takes approximately 13 minutes.
When the warm-up cycle is completed, the oven
will beep and display the
READY TO COOK.
INSTALLATION, SPECIFICATIONS, AND MAINTENANCE
10
9
876
12345
5
DAILY MAINTENANCE FOR THE NGC
Before cleaning, check with the store for custom
cleaning instructions.
When cleaning the oven, use only TurboChef Oven
Cleaner.
Any other cleaning products can damage
critical parts and may void warranty on those parts.
F
(260ºC) and may cause injury if not allowed
time to cool properly.
Step 2: Remove the Lower Access Panel
o
Wipe out any crumbs that have collected.
Step 3: Remove and Clean the Cooking Surface
o
If rack, wash, rinse, and sanitize.
o
If baking stone, gently dry-scrub with nylon pad.
If the stone gets wet, let it thoroughly air-dry.
Step 4: Lift Bottom Element
o
Be sure the bottom element is cool prior to lifting.
WARNING
: The bottom element operates at
appx. 1000ºF (537ºC).
Step 5: Remove Particles and Spray Oven Interior
TurboChef
with
o
Using a damp towel, remove large food particles.
o
If stubborn stain is present, sparingly spray
®
Oven Cleaner
TurboChef Oven Cleaner onto the stain.
o
Allow cleaner to penetrate for five (5) minutes.
x
o
DO NOT saturate the bottom of the oven with
water or oven cleaner.
Step 6: Clean Oven Interior
o
Using a nylon scrub pad, clean the oven door
and cook cavity.
CAUTION: DO NOT apply pressure to the
wave guide covers. Breaking will result in a
non-warranty service call.
Step 7: Wipe Out Oven Interior
o
Wipe oven door, bottom element, and cook
cavity using a damp towel.
Step 8: Clean Lower Access Panel Area
x
o
DO
spray any chemical in this area.
NOT
Step 9: Lower the Bottom Element and Reinstall the
Cooking Surface and Lower Access Panel
Step 10: Apply Oven Guard and Clean Oven Exterior
o
Spray Oven Guard on towel. Wipe sides of cook
cavity and inside of door.
x
o
DO NOT spray Oven Guard directly into cook
cavity or wipe on nozzle plates/bottom element.
o
Wipe the oven exterior with a clean, damp towel.
o
Oven is ready to turn on.
Theory of Operation
THEORY OF OPERATION
7
THEORY OF OPERATION
The TurboChef®NGC (Tornado®) oven utilizes
three
independent heat transfer mechanisms to
rapidly cook food.
The systems are as follows:
o
Convection
o
Infrared energy
o
Microwave 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.
Figure 5 below represents the oven’s different systems and the critical components of each system.
Should a problem arise with any of the compo
nents 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 CONVECTION SYSTEM
and/or
BOTTOM IR AND CCV. Focus on MICROWAVE
SYSTEM
if the oven is browning the food but not
heating the inside.
Part numbers are included on illustrations (where
applicable) and in the back of this manual. If an
item is not illustrated, the part number is provided
in the text.
Chapter 4
CONTROL SYSTEM
I/O Control Board
Keypad
Display
Mechanical Relays
Solid State Relay
Chapter 5
MICROWAVE SYSTEM
Magnetrons
High Voltage Transformers
Filament Transformers
High Voltage Capacitors
High Voltage Diodes
Fuses
Chapter 7
CONVECTION SYSTEM
Convection Heater
Blower Controller
Blower Motor
Hi-Limit Thermostat
Chapter 8
BOTTOM IR AND CCV
Bottom Infrared Element
Catalytic Converter
FIGURE 5: NGC (Tornado) Systems and Critical Components
8
THEORY OF OPERATION
GLOSSARY OF COMMON OPERATING TERMS
Off State
All the oven’s control systems are off and the cook cavity temperature is below 150ºF (66ºC).
Cool Down
A subset of the OFF STATE. During COOL DOWN, the oven will circulate the main convection blower until
the cook cavity temperature is below 150ºF (66ºC).
Ready State
The oven has successfully warmed to the predefined set temperature. At this point the oven control is
ready to receive cook commands via the keypad. The oven will maintain the set temperature in the
STATE.
READY
Set Temperature, Cook Cavity (CCSP)
Predefined temperature of the cook cavity at which the oven cooks.
Set Temperature, IR Element (IRSP and IRSI)
IRSP is the set temperature of the IR element during a given cook cycle. Settings are determined on a
per-recipe basis. IRSI is the set temperature of the IR element during the READY STATE (or “idle”). IRSI
setting can be adjusted in the TEST MODE (page 16).
Actual Temperature, Cook Cavity (TCC)
The actual temperature registered by the cook cavity thermocouple.
Actual Temperature, IR Element (TIR)
The actual temperature registered by the IR element.
Edit Mode
Enables the user to change recipe and CCSP/IRSP temperature settings.
Warm-Up
The mode in which the oven warms itself to the set temperature.
Soak
The mode in which the oven temperature has reached the CCSP, and remains in warmup for an addi
tional 8 minutes to allow cook cavity surfaces to warm. The oven will proceed to soak only if warm-up
was initiated when TCC < (CCSP - 126ºF) or TCC < (CCSP - 66ºC).
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, check oven statistics, and set the IRSI.
-
THEORY OF OPERATION
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.
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 can be set between 0 and 100% of the total cook time.
Total Cook Time
The total duration of a recipe.
9
Percentage (%) Time
An event subset that specifies the duration of the event. The sum of all event time percentages for a recipe
must equal 100%.
Percentage (%) Air
An event subset that specifies the relative amount of impingement airflow (speed of convection motor) dur
ing an event. Valid between 10 and 100%.
NOTE: Maximum 100% = 7100 RPM blower motor speed. Blower motor speed scale is linear.
Percentage (%) Microwave (WAV)
An event subset specifying the microwave cycle during the event. Valid between 0 and 100%. For example,
if WAV is set to 30%, then microwave would be present in the cook cycle for 3 out of every 10 seconds.
Fault Code
A code assigned to an instance 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 oven will also log faults F1
through F6 in the Fault Log. See page 11 for more detail on faults and for viewing the fault log.
-
Fault Codes
The NGC (Tornado®) oven has the ability to continual-
COOK COUNT
F1 BLOWER
F2 LOW TEMP
F3 MAG CURR
F4 MONITOR
F5 MAG TEMP
F6 TEMP
S/N XXXXXX
NGCVXXXX XXXXXX
0
0
0
0
0
0
0
FIGURE 6: Fault Log
FAULT CODES
monitor and log various fault conditions. Some
ly
fault conditions will terminate cook cycles, while
will not. Please refer to the fault code table
others
on page 12 for more detailed information.
When a fault is detected, the Fault Log will increment. However, if the fault is subsequently
cleared
by some action, whether service related or not, the
Fault Log will not decrement.
11
TO VIEW FAULT CODES
To view the Fault Log, simultaneously press the “4”
and “6” keys while the oven is in the OFF STATE.
all faults logged. Figure 6.
The oven will dis
play
Each fault will log up 255 instances before rolling
back to zero. To zero the log, see pages 14-15
TEST MODE).
(
: The Fault Log also displays cook counts,
NOTE
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 has only one event, the oven must complete
the entire cook cycle in order to count it.
FAULT CODE DEFINITIONS
F1: Blower Running Status Bad
Fault is displayed when the motor controller
indicates no running status.
The motor and motor controller are monitored
tinuously in all modes with special handling in
TEST and TEST MODE. If a fault is detected, the con-
con-
SELF
trol will terminate a cook cycle and display F1:
BLOWER. Upon turning on the oven, the control will
attempt
cessful, the
also cleared from the display at the onset of cooking
or when the blower motor is tested in TEST MODE.
to restart the motor. If the restart is suc
fault code will be cleared. The fault is
-
F2: Cook Temperature Low
Fault is displayed if the cook cavity temperature is
more than 84ºF (47ºC) below the set temperature
after five (5) seconds into a cook cycle
.
The fault is cleared from the display at the onset of
cooking if the cook cavity temperature is within
º
(47
84ºF
heater is tested in the
of the set temperature or when the
C)
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 from the display at the onset of
a cook cycle if the CT detects current or when the
magnetron is successfully energized in TEST MODE.
F4: Door Monitor Defective
Fault is displayed when the control detects that the
monitor interlock switch unlatches before the
pri
mary or secondary interlock switches.
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 from the display
when the oven is powered off and then back on.
-
12
FAULT CODES
: Door interlock switches are in parallel. See
NOTE
OVEN SCHEMATICS, pages 55-63. The fault is moni-
tored during a
cook cycle, or in SELF TEST when the
microwave is on.
F5: Magnetron Over Temperature
Fault is displayed when either magnetron thermostat is “open.”
The fault is cleared from the display at the onset of
a cook cycle if the thermostat is closed or when the
magnetron is successfully tested in TEST MODE.
F6: EC (Electrical Compartment) Temperature High
Fault is displayed when the EC thermocouple
exceeds 158ºF (70ºC). It is monitored once per
minute.
The fault is cleared from the display when the EC
FAULT CODE TABLE
thermocouple temperature is below the indicated
limit.
F7: Thermocouple Open
Fault does not log in counter. Fault is displayed
when the control detects that either the IR or CC
thermocouple is “open.”
o
999ºF/C indicates CC thermocouple is “open.”
o
1999ºF/C indicates IR thermocouple is
“open.”
Fault is cleared when the control detects continuity
on the open thermocouple circuit.
F8: Heat Low
Fault is not logged in counter. Displays during
WARM UP or SELF TEST if the cook cavity tempera-
ture (TCC) fails to rise at least 14ºF (7ºC) within a
given thirty (30) seconds.
FAULT CODE AND DESCRIPTIONWHEN ACTIVEREFER TO
F1: Blower Running Status Bad
F2: Cook Temperature Low
F3: Magnetron Current Low
F4: Door Monitor Defective
F5: Magnetron Over Temperature
F6: EC Temperature High
Thermocouple Open
F7:
F8: Heat Low
Warm - up
X
X
X
X
Idle Mode
X
X
X
Cook Mode
X
X
X
X
X
X
X
Self-Test
X
X
X
X
X
Page 22
Page 23
Page 34
Page 46
Page 28
Page 14
Page 21
Page 22, 49
Fault codes are listed in order of hierarchy. For example, if during cooking the oven experiences an F1
and F2 fault, the oven will report only the F1 fault because the software will halt all actions upon discovering the F1 fault. F7 and F8 faults are displayed on the primary screen and are not displayed or counted
in the Fault Log.
NOTE: 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 Log.
The Control System
GROUND
S
T
A
T
U
S OK
I/O COM
1
2
O
U
T
2
4
0
V
A
C
3 PHASE
3
4
4
6
5
2
1
3
I/O COM
E
N
A
B
L
E
2
0
0-240
VAC IN
S
P
D
2
3
0-10V
1
BMSC
K1
M
ECH
RELAY
+
24 VDC -
RELAY
M
ECH
K2
RELAY
M
ECH
K3
SSR
D
UAL
B
OARD
CONTROL
I
/
O
K
E
Y
P
A
D
VFD
D
I
S
P
L
A
Y
IR THERMOCOUPLE
E
C
THERMOCOUPLE
C
C
T
H
E
R
M
O
C
O
UPLE
SUPPLY
P
O
WER
2
4
V
D
C
IR ELEMENT COMMAND
C
O
NVECTION HEATER COMMAND
M
A
G
H
V
COMMAND
COMMAND
MAG FILAMENT
MONITOR
INTERLOCK
I
N
T
E
R
LOCK
INTERLOCK
+
2
4
V
DC
+24VDC
+
2
4
V
D
C
COMMON
CMD
C
O
M
MON
+
2
4
VDC
PRIMARY SWITCH
S
E
C
O
N
D
A
RY SWITCH
K6
M
ECH
RELAY
+
24 VDC -
+
24 VDC -
+
24 VDC -
VOLTAGE
C
O
M
M
AND
COMMON
VOLTAGE INPUT
V
O
L
T
A
G
E
K7
RELAY
- 24 VDC +
MAGNETRON COOLING FAN COMMAND
P
R
IMARY SWITCH
NC
NO
C
N
C
C
N
O
SECONDARY SWITCH
M
O
N
I
T
OR SWITCH
N
C
C
NO
3(+) 4(-)
3
(+) 4(-)
+V
-
V
L
N
A
(
-
)
C
(
+
)
C
(
+
)
A (-)
C (+)
A
(
-)
1 2
1
4
14
2
1
1
4
21
14
2
1
1 2
2
5
2
6
2
1
2
5
2
6
2
1
1
2
2
5
2
6
2
5
2
6
+24VDC
K5
K
4
(U.S. ONLY)
F
OR MORE DETAIL, SEE FIGURE 37
S
E
N
S
O
R
FIGURE
7:
NGC (Tornado
®
) Control System
13
U.S. ONLY
The Control System is comprised of the components
that signal, sense, command, and switch the oven’s
various components. Figure 7 shows a functional
diagram of all the components that make up the
Control System.
NOTE
be located on the drawings found throughout and
at the end of this manual.
THE CONTROL SYSTEM
: The part numbers for each component can
14
THE CONTROL SYSTEM
CONTROL SYSTEM COMPONENT DESCRIPTIONS
24 VDC Power Supply
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
240 VAC, 30 Amp, Double Pole, Double Throw, 24
VDC Relay Coil. Switches power to the magnetron
filament transformers.
K2 Mechanical Relay
240 VAC, 30 Amp, Double Pole, Double Throw, 24
VDC Relay Coil. Switches power to the magnetron
high voltage transformers.
K3 Mechanical Relay
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 or secondary interlock switches.
IR Thermocouple
Type K Thermocouple. Embedded in the IR element, the IR thermocouple measures the internal/sheath temperature of the IR element. Valid IR
set points are between 500ºF (260ºC) and 1150ºF
(621ºC). The display indicates 1999ºF/C if the
thermocouple
is “open
”.
EC Thermocouple (P/N 700-1199)
Type K Thermocouple. Thermocouple measures the
temperature of the electrical compartment. If the
temperature within the electrical compartment is
above 158ºF (70ºC), the control displays F6: EC
TEMP. The control board checks the EC tempera-
ture every 60 seconds.
CC Thermocouple
Type K Thermocouple. Thermocouple measures
the temperature of the re-circulating impingement
airflow. Valid CC set points vary depending on
software. If the
display indicates 999
º
F/C, the ther
mocouple is “open.”
-
K4/K5 SSR
240 VAC, Dual 40 Amp Solid State Relay. K4
(right) controls the convection heater and K5 (left)
controls the IR element.
K6 Mechanical Relay (North America Only)
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.
K7 Relay
24 VDC, 20 Amp, Sealed.Starts with command
from I/O board; switches magnetron cooling fan on
and off. Timer for switching off mag fan is 4:15
after filament switches off.
Interlock Switches
Primary, Secondary, and Monitor Interlock Switches .
Must be actuated by the oven door. When the door
opens, the order is: P, S, M.
BMSC
Proprietary Brushless DC Motor Controller.
Designed solely to operate the blower motor.
VFD (Display)
Vacuum Fluorescent Display.
Keypad
5x9 Matrix Membrane Switch. Keypad is connected
to the I/O control board via 14-pin flat cable.
Voltage Sensor (North America Only)
Proprietary device designed to measure incoming
line voltage and switch between 208 and 240 VAC
operation. The device measures and allows the user
to configure
the oven only when the oven is first
powered on. Voltage sensor will default at 240
VAC.
TEST MODE
The Test Mode allows the service technician to
operate the oven’s subsystems individually. It also
allows the operator to configure various presets.
THE CONTROL SYSTEM
CC 810F
TEST NGC XXXXX
IR 5000F
BLOWERHEATER
FAULT SMGTRON
STEST
IR ELE
P S MAt hWi
CC 810F
TEST NGC XXXXX
IR 5000F
DIAG
0
ELEC
COOKSF/C
ACCUM
IR SI
P S MAt hWi
FIGURE
9: Test Mode - Screen 1
FIGURE
10: Test Mode - Screen 2
FIGURE
8: Accessing Test Mode
15
To enter
Press the BACK key until the display is in the OFF
1.
STATE
Simultaneously press BACK and ENTER keys.
2.
TEST MODE (Figure 8):
.
3. When prompted, enter the access code: 9-4-2-8
and press
ENTER.
The TEST MODE displays the software version, actual cook chamber temperature, and actual IR element
temperature at the top of the screen. The TEST
MODE consists of 2 screens (Figures 9 and 10). To
display the second screen, press either the UP or
DOWN key. To test a component or sub-system,
press the corresponding soft key.
TEST FUNCTION OPTIONS
Blower Speed (Screen 1)
The BLOWER key increments the blower motor
speed in 10% increments. When the speed is
100%, the next press sets the speed to 0%.
Self-Test Function (Screen 1)
key initiates a self-test to test all major
STEST
The
components of the oven (including door switches).
To run the
key once.
/COOLING DOWN mode.
OFF
self-test, press the corresponding soft
Press the BACK key to return to the OVEN
Heater Test (Screen 1)
Press the HEATER key to turn the heater on. Heater
will remain on until key is pressed again to turn it
off. If the blower speed is 0, the blower speed is
set to idle airflow (10%).
Magnetron (Screen 1)
Press and hold the
MGTRON key to test the mag-
netrons. Doing so requires a 5-second warm-up
period. 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 cooling
fan for an extra 4 minutes, 15 seconds.
NOTE
cooling, open the oven door to further expedite.
Faults (Screen 1)
Pressing the FAULTS soft key will display all the
accumulated faults in the Fault Log. Press “0” to
zero the fault counter. For more information, see
page
: If this function is being used to expedite
.
11
IR ELE (Screen 1)
Pressing the IR ELE key will turn on the IR
element. When pressed, the screen will read IR
ELEMENT ON. Press the IR ELE key again to turn it
off.
16
THE CONTROL SYSTEM
Diagnostic Display (Screen 2)
DIAG key turns on or off the diagnostic display
The
feature. When this feature is enabled, the oven will
display temperature and cook cycle parameters when
the oven is cooking or idle.
In addition, the status indicators are displayed on the
bottom of the screen. When a status indicator
is
highlighted/backlit the corresponding system is off
or open. For
example:
W would indicate that the
Microwave System is off.
STATUS INDICATOR section below offers a more
The
detailed description of each indicator.
COOKS (Screen 2)
Press once to display the total number of cook counts
for all recipes. Press again to display the total amount
of time the oven has been in cook cycles.
ACCUM (Screen 2)
Press once to display the total amount of time the
magnetrons have been on. Press again to display the
total amount of time the oven has been on.
Electronic Compartment Temperature (Screen 2)
º
The
ELEC key displays the temperature inside the
electronic compartment.
F/C (Screen 2)
Changes how the oven’s temperature units are dis
/C key alternately selects Fahrenheit or
played. The
F
-
Celsius.
IR SI (Screen 2)
Displays the idle IR set point. This temperature is a
factory setting and should never be altered.
If an
incorrect temperature has been entered, consult the
factory before changing this value.
STATUS INDICATORS
See Figures 9 and 10 on page 15.
Primary switch – closed or open
P
SSecondary switch – closed or open
Monitor switch – closed or open
M
tMagnetron thermostats – closed or open
Main convection heater – off or on
h
iIR element – off or on
Blower motor controller – enabled or disabled
A
Microwave current – Less than or greater than 7
W
Amps*
* Microwave (W) status indicator is not
highlighted/backlit when the current is more
than 7 Amps.
Status indicators are displayed at the bottom
display screen when the oven is in
during normal oven operation if in
TEST MODE, or
DIAGNOSTIC MODE
of the
(DIAG was turned on). Refer to Figures 9 and 10.
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 in an energized or on state.
PROGRAMMING
Edit Mode
EDIT MODE enables the operator to manually alter
The
recipes
and the cook cavity temperature (CCSP).
To access EDIT MODE:
1. Simultaneously press the UP and DOWN keys.
2. When prompted, enter the access code “9” and
press the ENTER key.
then
: If this does not provide access, refer to page 19
NOTE
for enable/disable codes.
Changing the Cook Chamber Temperature
This temperature is a factory setting - exercise caution
before altering it. For best results, consult the factory
before changing this value.
To change
press
vary depending on software.
the correct
firm and advance to the next screen
Altering a Recipe
Most NGC (Tornado) oven models contain 128
unique recipes. The display shows two (2) pages each
with eight (8) recipe groups. Each recipe group contains eight (8) recipes. See Figures 11 and 12.
To alter a recipe:
1.
2. Enter the access code “9” and set the CCSP. The
3.
4.
the cook cavity temperature
(CCSP),
the UP and DOWN keys. Temperature ranges
Once you have selected
temperature, press the ENTER key to con-
.
Enter the EDIT MODE (see page 16).
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 key.
Select the recipe group that contains the
individual recipe you wish to alter. Select the recipe you
wish to alter by pressing the soft key corresponding to the recipe item. Figures 11 and 12.
Use the
the recipe settings. Use the keypad and ENTER key
UP and DOWN keys to navigate through
to alter any of the following three (3) parameters
(see Figure 13):
a.
Cook
time
Total duration of the cook cycle. Enter the
desired time and press
IR element temperature (IRSP)
b.
ENTER.
The temperature the lower radiant element
will maintain during the entire cook cycle.
Valid temperatures are between 500ºF (260ºC)
and 1150ºF (621ºC).
c. Events 1…6
key to enter values
Use the keypad and
ENTER
for % TIME, % AIR, and % WAV.
o
Sum of %
TIME for all events must = 100.
The operating system will not allow a
combination of events not equal to 100%.
o
The % AIR parameter is valid between 10
and 100%.
o
The % WAV (microwave) parameter is valid
between 0 and 100%.
5. After making changes, test
the recipe by
pressing the TEST soft key. Once the oven has
warmed to the CC set point, press the TEST
soft key again to begin the test cook.
6. Once satisfied with the recipe, press SAVE to
permanently store changes.
7. Press the
BACK key until exited from EDIT MODE.
DONE
SAVE
TIME
COOK
MORE
ENTER COOK TIME
00:20
START
FIGURE
15: Done Screen
FIGURE
16:
Time (Start) Screen
THE CONTROL SYSTEM
18
FIGURE
14: Inserting Smart Card
Loading a Menu from a Smart Card
OFF/COOLING
1. Ensure the oven is in the
DOWN mode.
2. Enable the
LOAD MENU function (page 19). The
OVEN
oven will return to the Off screen.
3. Remove the lower access panel (Figure 14).
4. Insert smart card into oven (Figure 14).
5. Press the bottom-left soft key.
6. Select
LOAD MENU FROM CARD. The menu on
the smart card will load to the oven.
7. When this process completes, the oven will
beep. Remove the smart card and reattach the
lower access panel.
8. If the oven is a Subway oven, disable the LOAD
MENU function (page 19). For all other ovens,
leave it enabled.
OVEN OPTIONS
Done Screen
To enable/disable the Done Screen (Figure 15), see
the next page. Enable the Done Screen to:
o
Cook an item longer after the end of a cook cycle.
o
Save an adjusted cook time (only if Time Screen is
also enabled).
Time Screen
To enable/disable the Time Screen (Figure 16), see
the next page. Enable the Time Screen to:
o
Adjust the cook time before initiating a cook cycle.
o
Save an adjusted cook time.
Snooze Mode
To enable/disable the Snooze Screen, see the next
page. Enabling the Snooze Screen will allow the oper
ator to set the oven in a mode during which all oven
operations are turned off, but the heaters remain on.
The cook cavity will remain at the set temperature,
and the IR temperature will drop 200ºF (104ºC)
below the IRSI. This allows fast recovery when the
oven is again turned on.
-
THE CONTROL SYSTEM
USER CONFIGURABLE OPTIONS - ENABLE/DISABLE CODES
The following codes enable and disable each function/screen listed. They do not take you to the function/screen.
19
After each code, press
ENTER. To enable, press 9 after entering code (except S-A-V-E, W-A-V-E). To disable, press
Save Menu to Card - step 1BACK & ENTER6-3-6-8 (M-E-N-U)
& ENTER7-2-8-3 (S-A-V-E)
Save Menu to Card - step 2
Snooze Screen
Time Screen (Figure 16)
Timed Mag Test
- Some codes are not available on some ovens.
- Oven must be in Off or Cooling Down mode.
USER CONFIGURABLE OPTIONS - ACCESS CODES
BACK
BACK & ENTER7-6-6-9 (S-N-O-Z)
BACK & ENTER8-4-6-3 (T-I-M-E)
& ENTER9-2-8-3 (W-A-V-E)
BACK
The following codes allow access to each function/screen listed. To enable/disable these codes (where applicable),
see above. After each code, press ENTER.
Function/Screen
Simultaneously PressEnter Key Code
Edit Recipe ModeUP & DOWN9 (or as specified - see “Set PIN” below)
Erase Menu*BACK & ENTER3-7-2-7 (E-R-A-S)
Load Menu from Card
Bottom-left, then upper-mid soft key
Master ResetBACK & ENTER9-4-7-1
Save Menu to Card
Set PIN**
& DOWN3-3-4-8 (E-D-I-T)
UP
Bottom-left, then lower-mid soft key
Test ModeBACK & ENTER9-4-2-8 (W-H-A-T)
Unit Test
BACK & ENTER8-6-4-8 (U-N-I-T)
View Cook Counts1 & 3
View Faults***
4 & 6
Zero Cook Counts*BACK & ENTER6-7-3-9 (O-R-E-Z)
- Oven must be in Off or Cooling Down mode.
* To execute, press 3 after entering code.
Set PIN after entering code. Accessing “Edit Recipe Mode” will now require new PIN instead of 9.
**
*** To view voltage, press ENTER. To initiate a self test, press the corresponding soft key from the voltage screen.
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