Accelerating the World of Cooking
TurboChef Service Manual
FOR THE TURBOCHEF NGC (TORNADO) OVEN
800.90
TURBO
Part Number: NGC-1007 / Revision D / September 2007
For further information call:
800.90
TURBO
+1 214.379.6000
Accelerating the World of Cooking
IMPORTANT SAFETY INFORMATION - PLEASE READ FIRST
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
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 Instructions i
General Safety Information i
Reducing Fire Risk i
Precautions to be Observed Before and During Servicing to Avoid Possible
Exposure to Excessive Microwave Energy ii
Grounding Instructions ii
Power Cord Replacement ii
RF Interference Considerations ii
Chapter 1: Installation, Specifications and Maintenance
Specs and Dimensions 1
Dimensions 1
Construction 1
Standard Features 1
Certifications 1
Packaging 1
Power Supply (Domestic and Intl Electrical Specifications) 1-2
Power Input 2
Delivery and Product Placement 2
Lifting and Placing the Oven 2
Built-In Installation 2
Installation Near Open Heat Source 3
Oven Restraint Kit 4
Setup and Initial Operation 4
Setup 4
Stacking 4
Programming 4
Initial Power-Up 4
Maintenance 5
Chapter 2: Theory of Operation
Theory of Operation 7
Glossary of Common Operating Terms 8
Chapter 3: Fault Codes
To View Fault Codes 11
Fault Code Definitions 11
Fault Code Table 12
Chapter 4: The Control System
Control System Schematic 13
Control System Component Descriptions 14
Test Mode 14
Test Function Options 15
Status Indicators 16
Table of Contents
Oven Options 18
User Configurable Options - Enable/Disable Codes 19
User Configurable Options - Access Codes 19
Control System Panel Parts 20
Control System Troubleshooting 21
Chapter 5: The Microwave System
Voltage Doubler Circuit Description 25
Monitor Circuit Description 25
Voltage Doubler Theory of Operation 26
Microwave System Parts 26
Microwave System Components 28
Wave Guide Cover Replacement 29
Wave Guide/Wave Guide Cover Parts 30
Wave Guide Replacement 30
High Voltage and Filament Transformer Replacement 30
Wiring the High Voltage Transformers 30
Wiring the Filament Transformers 31
Measuring RF Leakage for Microwave Safety 31
How to Test Microwave Components 32
Testing the High Voltage Diode 32
How to Check a Diode 32
How to Check a Capacitor 33
How to Check a Magnetron for Open/Shorted Filament 33
How to Check a High Voltage Transformer or Filament Transformer 33
High Voltage and Filament Transformer Resistance Table 33
Microwave System Troubleshooting 34
Chapter 6: The Oven Door
Removing/Reinstalling the Oven Door 37
Oven Door Parts 37
Adjusting the Oven Door 38
Preparing the Oven for Switch Adjustment 38
Oven Burn-In Procedure 38
Adjusting the Primary and Secondary Interlock Switches - Old Switch Setup 38
Primary and Secondary Interlock Switch Adjustments and Parts 39
Door Switch Assembly and Parts 40
Adjusting the Monitor Safety Switch - Old Switch Setup 40
Monitor Safety Switch Parts 40
Adjusting the Primary Interlock Switch - New Switch Setup 42
Primary Switch Adjustment and Parts 42
Adjusting the Secondary and Monitor Interlock Switches - New Switch Setup 43
Secondary and Monitor Safety Switch Parts 43
Oven Door Assembly 44
Oven Door Parts 44
Screw Torque Chart 45
Interlock Switch Troubleshooting 46
Chapter 7: The Convection Circuit
Convection Circuit Components 47
Convection Circuit/Blower Motor Parts 48
Convection Circuit Troubleshooting 49
Motor Winding Resistances Table 50
Chapter 8: IR Element and Catalytic Converter
Components 51
IR Element and Catalyst Removal 51
Removing the IR Element 51
Removing & Installing the Catalytic Converter 52
Installing a New IR Element 52
IR Element and Catalytic Converter Parts 52
Chapter 9: Schematics and Schematic Components
Schematic Parts 53
Line Voltage Components 53
Low Voltage Components 53
Wire Harness Replacement P/N’s 53
I/O Control Board Item Identification and Test Point Locations 53
Schematic - I/O Board 54
Oven Schematics 55 - 63
Chapter 10: Service Parts and Illustrations
Figure 7: NGC (Tornado) Control System 65
Figure 17: Control System Panel Enclosure and Parts 66
Figure 18: Monitor Circuit - Shown in Failsafe State 67
Figure 20: Microwave System Parts 67
Figure 21: Microwave System Parts 68
Figure 22: Wave Guide Cover/Wave Guide Removal and Replacement 68
Figure 24 & 25: High Voltage Diode and Magnetron 69
Figure 26: Oven Door Removal and Parts 69
Figure 29: Primary and Secondary Adjustment and Parts - Old Switch Setup 70
Figure 30: Door Switch Assembly and Parts 70
Figure 31: Motor Switch Adjustment and Assembly - Old Switch Setup 71
Figure 32: Primary Interlock Adjustment and Parts - New Switch Setup 71
Figure 33 & 34: Secondary and Monitor Adj. and Assy. - New Switch Setup 72
Figure 35: Oven Door Assembly 73
Figure 37: Convection Circuit Block Diagram 74
Figure 38: Convection Circuit Assembly and Parts 75
Figure 39: IR Element and Catalytic Converter Parts and Assembly 76
Figure 46: Covers and Miscellaneous Parts - Non-SBK Ovens 77
Figure 47: Covers and Miscellaneous Parts - SBK Ovens 78
Chapter 11: Comprehensive Part List
Comprehensive Part List 79
i
INTRODUCTION
IMPORTANT SAFETY INSTRUCTIONS
Strictly adhere to the following safety precautions to reduce the risk of:
Burns
Electric shock
Fire
Injury
Damage to oven or property near oven
Exposure to excessive microwave energy
GENERAL SAFETY INFORMATION
Read all instructions before using the appliance.
Install or locate this appliance only in accordance with the provided installation instructions.
Some products such as whole eggs and sealed containers (e.g., closed glass jars) may explode and should not be
heated in this oven.
Use this appliance only for its intended use as described in this manual.
This appliance should be serviced only by qualified service personnel. Contact the nearest authorized service
facility for examination, repair, or adjustment.
Keep cord away from heated surfaces.
x
DO NOT
allow children to use this appliance.
x
DO NOT use corrosive chemicals or vapors in this appliance - it is not designed for industrial or laboratory use.
x
DO NOT operate this appliance if it has a damaged cord or plug, is not working properly, or has been damaged
or dropped. See
POWER CORD REPLACEMENT
, page ii.
x
DO NOT cover or block any openings on the appliance.
x
DO NOT store this appliance outdoors.
x
DO NOT
use this product near water (e.g., near a kitchen sink, in a wet basement, near a swimming pool).
x
DO NOT immerse cord or plug in water.
x
DO NOT let cord hang over the edge of table or counter.
x
DO NOT use a water jet for cleaning. See the maintenance section of this manual on page 5 for proper cleaning
procedures.
REDUCING FIRE RISK
Remove wire twist-ties from paper or plastic bags used to facilitate cooking in the oven.
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
If smoke is observed, switch off or unplug the oven. Keep the door closed to stifle any flames.
x
DO NOT
use the cook cavity for storage purposes.
x
DO NOT
overcook food. Carefully attend the oven if paper, plastic, or other combustible materials are placed
inside the oven to facilitate cooking.
x
DO NOT leave paper products, cooking utensils, or food in the cavity when not in use.
SAVE THESE INSTRUCTIONS
ii
INTRODUCTION
PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO
EXCESSIVE MICROWAVE ENERGY
(a) DO NOT operate or allow the oven to be operated with the door open.
(b) Make the following safety checks on all ovens to be serviced before activating the magnetron or other
microwave source, and make repairs as necessary: (1) interlock operation, (2) proper door closing,
(3) seal and sealing surfaces (arcing, wear, and other damage), (4) damage to or loosening of hinges
and latches, (5) evidence of dropping or abuse.
(c) Before turning on microwave power for any service test or inspection within the microwave
generating compartments, check the magnetron, wave guide or transmission line, and cavity for
proper alignment, integrity, and connections.
(d) Any defective or misadjusted components in the interlock, monitor, door seal, and microwave
generation and transmission systems shall be repaired, replaced, or adjusted by procedures described
in this manual before the oven is released to the owner.
(e) A microwave leakage check to verify compliance with the Federal performance standard should be
performed on each oven prior to release to the owner.
GROUNDING INSTRUCTIONS
This appliance must be grounded. In the event of an electrical short circuit, grounding reduces the risk of
electric shock by providing an escape wire for the electric current. This oven is equipped with a cord that
has a grounding wire with a grounding plug, which must be plugged into an outlet that is properly installed
and grounded. Consult a qualified electrician or serviceman if uncertain about the ability to follow grounding instructions or if doubt exists as to whether the appliance is properly grounded.
x
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:
Increase the physical separation between this oven and the sensitive equipment.
If the sensitive device can be grounded, do so following accepted grounding practices.
If battery-powered microphones are being affected, ensure that the batteries are fully charged.
Keep sensitive equipment on separate electrical circuits if possible.
Route intercom wires, microphone wires, speaker cables, etc. away from the oven.
Installation, Specifications,
and Maintenance
Standard Features
Recirculating airpath with patented catalytic converter
system
Multi-speed convection blower
Independently-controlled bottom browning element
Stackable design
Smart Voltage Sensor Technology (North America only)
Factory-programmed, customizable menu settings
Smart Card for remote programming
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
EXTERIOR COOK CAVITY
Height 19” (483 mm) 8” (203 mm)
with legs 23” (584 mm)
Width 26” (660 mm) 15.5” (394 mm)
Depth 25.7” (653 mm) 14.7” (373 mm)
with handle 28.2” (716 mm)
Weight 190 lbs. (86 kg)
WALL CLEARANCE
Back 0” (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
430 stainless steel front, top and sides.
4” (102 mm) adjustable legs
Cool to the touch handle
INTERIOR
304 stainless steel line
Fully insulated cooking chamber
Removable assorted cooking surfaces
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 countertop 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:
Minimum of 300 cfm (8.5 cmm) of supplement flow
within the cabinet.
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 product 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:
Verify oven location has a minimum 6" (152 mm)
clearance on top and minimum 2" (51 mm) of
clearance on each side.
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.
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.
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
800.90
TURBO / +1 214.379.6000.
SETUP AND INITIAL 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.
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.
FIGURE 4: Properly Stacked NGC Ovens
INSTALLATION, SPECIFICATIONS, AND MAINTENANCE
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
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.
Supplies and Equipment
TurboChef Oven Cleaner (P/N 103180 USA,
103380 Intl), Oven Guard (P/N 103181 USA,
103381 Intl), nylon scrub pad, cleaning towel
Step 1: Prepare the Oven
Turn oven off by pressing the BACK key.
The oven will display OVEN OFF/COOLING DOWN.
x
DO NOT attempt to clean oven during the cool
down cycle. Cooling takes appx. 90 minutes.
WARNING: The oven operates at appx. 500
º
F
(260ºC) and may cause injury if not allowed
time to cool properly.
Step 2: Remove the Lower Access Panel
Wipe out any crumbs that have collected.
Step 3: Remove and Clean the Cooking Surface
If rack, wash, rinse, and sanitize.
If baking stone, gently dry-scrub with nylon pad.
If the stone gets wet, let it thoroughly air-dry.
Step 4: Lift Bottom Element
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
with TurboChef
®
Oven Cleaner
Using a damp towel, remove large food particles.
If stubborn stain is present, sparingly spray
TurboChef Oven Cleaner onto the stain.
Allow cleaner to penetrate for five (5) minutes.
x
DO NOT saturate the bottom of the oven with
water or oven cleaner.
Step 6: Clean Oven Interior
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
Wipe oven door, bottom element, and cook
cavity using a damp towel.
Step 8: Clean Lower Access Panel Area
x
DO NOT spray any chemical in this area.
Step 9: Lower the Bottom Element and Reinstall the
Cooking Surface and Lower Access Panel
Step 10: Apply Oven Guard and Clean Oven Exterior
Spray Oven Guard on towel. Wipe sides of cook
cavity and inside of door.
x
DO NOT
spray Oven Guard directly into cook
cavity or wipe on nozzle plates/bottom element.
Wipe the oven exterior with a clean, damp towel.
Oven is ready to turn on.
10
9
876
1 2 3 4 5
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:
Convection
Infrared energy
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 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
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
THEORY OF OPERATION
8
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
READY STATE.
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 additional 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
9
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.
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) during 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
11
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 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.
TO VIEW FAULT CODES
To view the Fault Log, simultaneously press the “4”
and “6” keys while the oven is in the
OFF STATE.
The oven will display all faults logged. Figure 6.
Each fault will log up 255 instances before rolling
back to zero. To zero the log, see pages 14-15
(
TEST MODE).
NOTE: The Fault Log also displays cook counts,
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 continuously in all modes with special handling in
SELF
TEST
and TEST MODE. If a fault is detected, the con-
trol will terminate a cook cycle and display
F1:
BLOWER. Upon turning on the oven, the control will
attempt to restart the motor. If the restart is successful, the fault code will be cleared. The fault is
also cleared from the display at the onset of cooking
or when the blower motor is tested in
TEST MODE.
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
84ºF (47ºC) 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 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 primary 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.
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
FAULT CODES
12
NOTE: Door interlock switches are in parallel. See
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
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.”
999ºF/C indicates CC thermocouple is “open.”
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 temperature (TCC) fails to rise at least 14ºF (7ºC) within a
given thirty (30) seconds.
FAULT CODE AND DESCRIPTION WHEN ACTIVE REFER 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
F7: Thermocouple Open
F8: Heat Low
FAULT CODE TABLE
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.
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
The Control System
THE CONTROL SYSTEM
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: The part numbers for each component can
be located on the drawings found throughout and
at the end of this manual.
GROUND
STATUS OK
I/O COM
1
2
OUT
240 VAC
3 PHASE
3
4
4
6
5
2
1
3
I/O COM
ENABLE
200-240
VAC IN
SPD
2
3
0-10V
1
BMSC
K1
MECH
RELAY
+ 24 VDC -
RELAY
MECH
K2
RELAY
MECH
K3
SSR
DUAL
BOARD
CONTROL
I/O
KEYPAD
VFD
DISPLAY
IR THERMOCOUPLE
EC THERMOCOUPLE
CC THERMOCOUPLE
SUPPLY
POWER
24VDC
IR ELEMENT COMMAND
CONVECTION HEATER COMMAND
MAG HV
COMMAND
COMMAND
MAG FILAMENT
MONITOR
INTERLOCK
INTERLOCK
INTERLOCK
+24VDC
+24VDC
+24VDC
COMMON
CMD
COMMON
+24VDC
PRIMARY SWITCH
SECONDARY SWITCH
K6
MECH
RELAY
+ 24 VDC - + 24 VDC - + 24 VDC -
VOLTAGE
COMMAND
COMMON
VOLTAGE INPUT
VOLTAGE
K7
RELAY
- 24 VDC +
MAGNETRON COOLING FAN COMMAND
PRIMARY SWITCH
NC
NO
C
NC
C
NO
SECONDARY SWITCH
MONITOR SWITCH
NC
C
NO
3(+) 4(-)
3(+) 4(-)
+V
-V
L
N
A (-)
C (+)
C (+)
A (-)
C (+)
A (-)
12
14
14
2
1
14
21
14
2
1
12
25 26
2
1
25 26
2
1
1
2
25 26
25 26
+24VDC
K5
K4
(U.S. ONLY)
FOR MORE DETAI L, SEE FIGURE 37
SENSOR
FIGURE 7: NGC (Tornado) Control System
13
U.S. ONLY
THE CONTROL SYSTEM
14
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.
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.
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 999ºF/C, the thermocouple is “open.”
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
To enter TEST MODE (Figure 8):
1. Press the
BACK key until the display is in the
OFF
STATE
.
2. Simultaneously press
BACK and ENTER keys.
3. When prompted, enter the access code: 9-4-2-8
and press
ENTER.
The
TEST MODE displays the software version, actu-
al 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%.
NOTE: If this function is being used to expedite
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
11.
Self-Test Function (Screen 1)
The
STEST key initiates a self-test to test all major
components of the oven (including door switches).
To run the self-test, press the corresponding soft
key once. Press the
BACK key to return to the OVEN
OFF
/COOLING DOWN mode.
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.
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.
CC 810F
TEST NGC XXXXX
IR 500
0
F
BLOWER HEATER
FAULTS MGTRON
STEST
IR ELE
PSM A
t hWi
CC 810F
TEST NGC XXXXX
IR 500
0
F
DIAG
0
ELEC
COOKS F/C
ACCUM
IR SI
PSM A
t hWi
FIGURE
9: Test Mode - Screen 1
FIGURE
10: Test Mode - Screen 2
FIGURE
8: Accessing Test Mode
15
THE CONTROL SYSTEM
16
Diagnostic Display (Screen 2)
The
DIAG key turns on or off the diagnostic display
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.
The
STATUS INDICATOR section below offers a more
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)
The
º
ELEC key displays the temperature inside the
electronic compartment.
F/C (Screen 2)
Changes how the oven’s temperature units are displayed. The
F/C key alternately selects Fahrenheit or
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.
P Primary switch – closed or open
S Secondary switch – closed or open
M Monitor switch – closed or open
t Magnetron thermostats – closed or open
h Main convection heater – off or on
i IR element – off or on
A Blower motor controller – enabled or disabled
W Microwave current – Less than or greater than 7
Amps*
* Microwave (
W) status indicator is not
highlighted/backlit when the current is more
than
7 Amps.
Status indicators are displayed at the bottom of the
display screen when the oven is in
TEST MODE, or
during normal oven operation if in
DIAGNOSTIC MODE
(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
The
EDIT MODE enables the operator to manually alter
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
then press the
ENTER key.
NOTE: If this does not provide access, refer to page 19
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 the cook cavity temperature (CCSP),
press the UP and DOWN keys. Temperature ranges
vary depending on software. Once you have selected
the correct temperature, press the
ENTER key to con-
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 con-
tains eight (
8) recipes. See Figures 11 and 12.
To alter a recipe:
1. Enter the
EDIT MODE (see page 16).
2. Enter the access code “9” and set the CCSP. 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 key.
3. 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.
4. Use the
UP and DOWN keys to navigate through
the recipe settings. Use the keypad and
ENTER key
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
ENTER.
b. IR element temperature (IRSP)
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
Use the keypad and
ENTER key to enter values
for %
TIME, % AIR, and % WAV.
Sum of % TIME for all events must = 100.
The operating system will not allow a
combination of events not equal to 100%.
The % AIR parameter is valid between 10
and 100%.
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.
GROUP A
EDIT GROUPS
GROUP B
GROUP C
GROUP D
GROUP E
GROUP F
GROUP G
GROUP H
ITEM 1
GROUP A
ITEM 2
ITEM 3
ITEM 4
ITEM 5
ITEM 6
ITEM 7
ITEM 8
< GROUP 1 >
SAVE
TEST
ITEM 1
COUNT
COOK TIME
IR SETPT
%TIME %AIR %WAV
1 XXX
2 XXX
3 XXX
4 XXX
5 XXX
6 XXX
XXX
XXX
XXX
XXX
XXX
XXX
XXX
XXX
XXX
XXX
XXX
XXX
0
00:00
500
0
F
FIGURE 11: Select Group
FIGURE 12: Select Recipe FIGURE 13: Edit Recipe Settings
17
THE CONTROL SYSTEM
Loading a Menu from a Smart Card
1. Ensure the oven is in the
OVEN OFF/COOLING
DOWN
mode.
2. Enable the
LOAD MENU
function (page 19). The
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:
Cook an item longer after the end of a cook cycle.
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:
Adjust the cook time before initiating a cook cycle.
Save an adjusted cook time.
Snooze Mode
To enable/disable the Snooze Screen, see the next
page. Enabling the Snooze Screen will allow the operator 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.
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
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.
After each code, press
ENTER. To enable, press 9 after entering code (except S-A-V-E, W-A-V-E). To disable, press
any key (except 9) after entering code.
Function/Screen Simultaneously Press Enter Key Code
Done Screen w/out “Save Time”
BACK & ENTER 3-6-6-3 (D-O-N-E)
Done Screen w/ “Save Time” - step 1
BACK & ENTER 3-6-6-3 (D-O-N-E)
Done Screen w/ “Save Time” - step 2
BACK & ENTER
8-4-6-3 (T-I-M-E)
Edit Recipe Mode
UP & DOWN 8-4-3-3 (T-I-D-E)
Load Menu from Card
BACK & ENTER 6-3-6-8 (M-E-N-U)
Save Menu to Card - step 1
BACK & ENTER 6-3-6-8 (M-E-N-U)
Save Menu to Card - step 2
BACK & ENTER 7-2-8-3 (S-A-V-E)
Snooze Screen
BACK & ENTER 7-6-6-9 (S-N-O-Z)
Time Screen (Figure 16)
BACK & ENTER 8-4-6-3 (T-I-M-E)
Timed Mag Test
BACK & ENTER 9-2-8-3 (W-A-V-E)
- Some codes are not available on some ovens.
- Oven must be in Off or Cooling Down mode.
USER CONFIGURABLE OPTIONS - ACCESS CODES
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 Press Enter Key Code
Edit Recipe Mode
UP & DOWN 9 (or as specified - see “Set PIN” below)
Erase Menu*
BACK & ENTER 3-7-2-7 (E-R-A-S)
Load Menu from Card Bottom-left, then upper-mid soft key
Master Reset
BACK & ENTER 9-4-7-1
Save Menu to Card Bottom-left, then lower-mid soft key
Set PIN**
UP & DOWN 3-3-4-8 (E-D-I-T)
Test Mode
BACK & ENTER 9-4-2-8 (W-H-A-T)
Unit Test
BACK & ENTER 8-6-4-8 (U-N-I-T)
View Cook Counts 1 & 3
View Faults*** 4 & 6
Zero Cook Counts*
BACK & ENTER 6-7-3-9 (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.
19
THE CONTROL SYSTEM
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