TurboChef i5 Service Manual
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TurboChef i5 Service Manual

Turbo chef technologies rapid cook oven service manual
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Accelerating the World of Cooking
TM
Service Manual
i5
F O R T H E T U R B O C H E F
R A P I D C O O K O V E N

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Summary of Contents for TurboChef i5

  • Page 1 Accelerating the World of Cooking Service Manual F O R T H E T U R B O C H E F R A P I D C O O K O V E N...
  • Page 3 For further information, call 800.90TURBO +1 214.379.6000...
  • Page 4 The information contained in this manual is important for the proper installation, use, maintenance, and repair of this oven. Follow these procedures and instructions to help ensure satisfactory baking results and years of trouble-free service. Errors – descriptive, typographic, or pictorial – are subject to correction. Specifications are subject to change without notice.

  • Page 5: Table Of Contents

    Table of Contents Safety Instructions General Safety Information Reducing Fire Risk Grounding Instructions Power Cord Replacement Precautions to be Observed Before and During Servicing to Avoid Possible Exposure to Excessive Microwave Energy RF Interference Considerations Specifications and Installation Theory of Operation Certifications Dimensions Oven Construction...
  • Page 6 Resetting the Oven Turning Oven Options On/Off Setting the Language Setting the Date/Time Test Mode - Testing Oven Parts Test Mode - Status Indicators Test Mode - Fault Log Test Mode - Turning On/Off Diagnostic Mode Test Mode - Self Test Test Mode - Manufacturing Mode Microwave Leakage Test (How to Use Oven for Testing) Microwave Power Test...
  • Page 7 Overview of the Microwave System Capacitors Testing a Capacitor Filament Transformers Wiring the Filament Transformers High-Voltage Transformers Wiring the High-Voltage Transformers Testing a Filament or High-Voltage Transformer High-Voltage Diodes Testing a High-Voltage Diode Magnetrons Testing a Magnetron for an Open/Shorted Filament Stirrer Motor and Assembly Wave Guides Troubleshooting...
  • Page 8 Troubleshooting Overview of Troubleshooting Fault Code Descriptions Fault Code Troubleshooting - F1 Blower Running Status Bad Fault Code Troubleshooting - F2 Cook Temperature Low Fault Code Troubleshooting - F3 Magnetron Current Low Fault Code Troubleshooting - F4 Door Monitor Defective Fault Code Troubleshooting - F5 Magnetron Over Temperature Fault Code Troubleshooting - F6 Electrical Compartment Temperature High Fault Code Troubleshooting - F7 Open RTD...

  • Page 9: Safety Instructions

    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, or possible exposure to excessive microwave energy. General Safety Information Read all instructions before using this appliance. Read and follow the specific "Precautions to be Observed Before and During Servicing to Avoid Possible Exposure to Excessive Microwave Energy"...

  • Page 10: Grounding Instructions

    RF Interference Considerations The i5 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 electro- magnetic compatibility at the time of manufacture.

  • Page 11: Specifications And Installation

    Specifications and Installation...

  • Page 12: Theory Of Operation

    This manual includes instructions for servicing, troubleshooting, installing, cleaning, and operating the i5 oven. If you have questions that are not addressed in this manual, contact Technical Service (800.90TURBO, +1 214-379-6000) or your Authorized Distributor.

  • Page 13: Electrical Specifications

    Voltage: 220 VAC Frequency: 60 Hz Current: 48 amps Max Input: 10000 watts Plug: NEMA 6-50P i5 JK model (i5-9500-8-JK) - 50 Hz (i5-9500-10-JK) - 60 Hz Voltage: 200 VAC Frequency: 50 or 60 Hz Current: 46 amps Max Input: 9000 watts...

  • Page 14: Unpacking Instructions

    Figure 2: Hand Grip Locations Install or locate this appliance only in accordance with the instructions below. Unpacking Instructions 1. Remove oven from packaging. 2. Before discarding packaging, check thoroughly for accessories, consumables, and literature. 3. Discard packaging. 4. Check cook cavity thoroughly for accessories, consumables, and literature.

  • Page 15: Installation Near Open Heat Source

    SPECIFICATIONS AND INSTALLATION Installation Near Open Heat Source See Figure 4, page 5. When placing a TurboChef oven near an open heat source, strictly adhere to the following: - If the oven is being placed near a grill or stove, a divider must exist between the oven and the open heat source, with a minimum of 6”...
  • Page 16 Above Counter Top Grill Figure 4: Installation Near Open Heat Source 32.0” (813 mm) 27.8” (706 mm) Figure 5: Oven Cart Dimensions TurboChef i5 Oven 6” (152 mm) Minimum Counter Top / Table Partition 24.3” (618 mm) Above Counter Top Deep Fryer 12”...
  • Page 17 SPECIFICATIONS AND INSTALLATION This page intentionally left blank.

  • Page 18: Daily Maintenance

    Daily Maintenance...
  • Page 19 Daily Maintenance The following steps will help maintain your i5 Oven. Use only TurboChef Oven Cleaner and Oven Guard. The use of any other cleaning products can damage critical oven components, resulting in a non-warranty service call. Step 1: Prepare the Oven WARNING: Oven operates at approximately 450°F (232°C) and may cause...
  • Page 20 DAILY MAINTENANCE Step 7 Step 8 Step 9 Step 10 Step 11 Step 12 Step 13 Step 7: Clean and Dry the Oven Door CAUTION: DO NOT spray oven cleaner directly onto the oven door gasket (reference “A” in adjacent photo) or saturate it with water. CAUTION: DO NOT scrub or attempt to clean the oven door gasket.

  • Page 21: Oven Controls And Cooking

    Oven Controls and Cooking...

  • Page 22: Oven Controls

    Figure 6: Oven Controls Oven Controls 1. Info Key When the oven is off or cooling down, press to access the (see page 13). INFO MODE 2. On/Off Key When the oven is cooling down or off, press to turn on the oven. When the oven is on or warming up, press to turn off the oven.

  • Page 23: Cooking

    OVEN CONTROLS AND COOKING OVEN OFF READY TO CLEAN SELECT COOK TEMPERATURE 500F 450F 375F 350F WARMING UP OVEN TCC = 244F SET POINT= 500F WARMING UP 08:00 OVEN TCC = 500F SET POINT= 500F Figure 7: Standard Operation Modes Cooking This section explains how to cook a food product by describing the “standard operation”...

  • Page 24: Mode 2: Temperature Select

    Mode 2: Temperature Select NOTE: If cooking with only one temperature, this screen will be bypassed. The i5 Oven can store up to four different cook temperature settings. Each temperature setting has 5 food groups assigned to it, each consisting of 10 food recipes (50 recipes per temperature setting).

  • Page 25: Mode 7: Cooking

    OVEN CONTROLS AND COOKING can be turned on or off ADJUST TIME MODE from the “Options” screen (see page 14). It is turned off by default. Happens When... is enabled and a food item ADJUST TIME MODE is selected from MODE Goes To...

  • Page 26: Overview Of The Info Mode

    - View the operating voltage (North America models only) - Access the fault log - Access service phone numbers - Reset the oven S/N: i5-DXXXXXX SOFTWARE VERSION INFO 1 MENU P/N AND REV LAST COOK: 500F SERVICE NUMBERS...
  • Page 27 Info Mode...

  • Page 28: Resetting The Oven

    INFO MODE Resetting the Oven Resetting the oven is one way to potentially clear an error message, should one occur. From screen 1 of , press the R5 soft key. INFO MODE Turning Oven Options On/Off Figure 12. From screen 2 of the INFO MODE key to access the “Options”...

  • Page 29: Test Mode - Testing Oven Parts

    Test Mode - Testing Oven Parts From screen 2 of the Info mode, press the L1 soft key to access . When prompted, enter TEST MODE the password 9 4 2 8 and press the Enter key. From , the oven’s components can be TEST MODE tested independently, or a comprehensive/ selective self-test can be run.

  • Page 30: Test Mode - Self Test

    INFO MODE Test Mode - Self Test From , press the R4 soft key to access the TEST MODE “Self Test” screen (Figure 15). From the “Self Test” screen: - L1 soft key initiates a comprehensive self test. The oven will check the door switches, blowers, magnetrons, and heaters in sequence.

  • Page 31: Serial Number Edit

    Serial Number Edit Press the L4 soft key to access the “Edit Serial Number” screen. To edit the serial number: - Use the number/letter keys to change a character. After one second, the cursor will advance to the next character. - Press the R3 soft key to advance to the next character.

  • Page 32: Updating The Software

    INFO MODE Updating the Software From the Oven Off screen, 1. Insert the smart card (see Figure 21). If multiple smart cards are required, ensure the correct smart card is loaded first. 2. From the COOLING DOWN mode, press and hold the Info key until the oven resets (approximately 5 seconds).

  • Page 33: Edit Mode

    Edit Mode...

  • Page 34: Overview Of The Edit Mode

    - 200 (all) Available to Cook: Single vs. Multiple Temperature Mode The i5 Oven is capable of utilizing four unique set temperatures. By default, the oven operates in “Single Temperature” mode, in which all four temperatures are the same. By contrast, if more than one temperature is specified in the oven will operate in “Multiple Temperature”...

  • Page 35: Changing Set Temperatures

    2. Select a “block” of food groups by pressing the corresponding right-side soft key (Figure 22). NOTE: Earlier i5 software versions store only two temperatures, each containing 2 food group “blocks.” 3. Select the group that contains the recipe(s) you want to edit (Figure 23).

  • Page 36: Changing Recipe Settings

    Changing Recipe Settings Recipe settings consist of the following: - Up to eight “events” or stages of the cook cycle. - Cook time. To change recipe settings, 1. Place the oven in (see page 14). EDIT MODE 2. Access the “Food Group” screen (page 20). 3.
  • Page 37 EDIT MODE This page intentionally left blank.

  • Page 38: Oven Systems

    Oven Systems...

  • Page 39: Blower Motor (Bottom)

    Convection System The convection system is designed to rapidly heat, clean, and recirculate air into the cook cavity. This section contains information about the following components: - Blower motor (bottom) - Blower motor (top) - Blower motor controller - Heater element - Jetplate (bottom) - Jetplate (top) - Stirrer motor and assembly...

  • Page 40: Troubleshooting

    OVEN SYSTEMS Troubleshooting Convection System The following faults may occur in relation to the convection system: - F1: Blower (see page 39) - F2: Low Temp (see page 40) - F6: EC Temp (see page 43) - F7: Thermo (see page 43) - F8: Heat Low (see page 44) The following cooking performance issues may occur in relation to the convection system:...
  • Page 41 Oven Frame Remove Bolts SM Switches Oven Door Hinge Figure 26A: Properly Adjusted Door - Side Views Tap in this corner Figure 26B: Door Misaligned Variation 1 - Side Views Figure 26C: Door Misaligned Variation 2 - Side Views Oven Frame Remove Bolts P Switch...

  • Page 42: Adjusting The Door Switches

    OVEN SYSTEMS Interlock Switches The primary, secondary, and monitor interlock switches engage and disengage in sequence to ensure a proper seal. When the door is opened, the switch sequence is P, S, M. Subsequently, the sequence is M, S, P when the door is closed. Adjusting the Door Switches WARNING: Procedure requires work while the oven is hot.

  • Page 43: Measuring Rf Leakage For Microwave Safety

    Step 5 = Loosen, Step 7 = Tighten, Step 8 = Loosen Slightly Step 4 Step 3 Figure 27: Counter Balance Adjustment Measuring RF Leakage for Microwave Safety WARNING: Procedure requires work while the oven and water loads are hot. As a result, exercise extreme caution when testing.

  • Page 44: Troubleshooting

    OVEN SYSTEMS Figure 28: Survey Meter Placement 5. Close the oven door and press the Enter key. The microwave system will turn on. 6. Position the microwave survey meter as shown in Figure 28, above. 7. Measure microwave emission around the door, moving the meter sensor at 0.5 inches/second.

  • Page 45: Capacitors

    Microwave System The i5 oven employs two independent microwave systems (left and right). In the case of an over- current situation relative to the left system, the F3 fuse will blow. In the case of an over-current situation relative to the right system, the F4 fuse will blow.
  • Page 46 OVEN SYSTEMS NOTE: The terminals with the orange dot or the orange wire always go to Terminal 3 on US models. To verify correct wiring (International), measure the voltage between the taps on FT1 and FT2. The voltage must be 220 VAC (Latin America), 200 VAC (Japan), or 230 VAC (International).
  • Page 47 High Voltage Transformers NGC-3062-1 NGC-3062-2 NGC-3062-3 Filament Transformers NGC-3061-1 NGC-3061-2 NGC-3061-3 High Voltage and Filament Transformer Resistance Table When the high-voltage winding starts to go toward negative, the high-voltage diode becomes non- conducting with the charged high-voltage capacitor in series with the high-voltage winding. When the transformer gets to its negative peak of -2400 VPK, the voltage applied to the filament is negative 4500 volts.

  • Page 48: Testing A Magnetron For An Open/Shorted Filament

    OVEN SYSTEMS Magnetrons Figure 30. Magnetrons supply the RF energy at 2.45 GHz and begin to oscillate when they are supplied with approximately 4.1 kVDC at approximately .350 mA. During operation each magnetron will output a nominal 1 kW of power. If replacement is required, conduct a microwave leakage test (page 27) after installation of new magnetron.

  • Page 49: Control Board

    Control System This section contains information about the following components: - Control board - Display - Electrical compartment cooling fans - Electrical compartment cooling fan thermostat - Electrical compartment thermocouple - EMI Filter - Fuses - High-limit thermostat - Keypad - Magnetron cooling fans - Magnetron thermostats - Power Supply...

  • Page 50: Magnetron Cooling Fans

    OVEN SYSTEMS High Limit Thermostat The high limit thermostat is a 250 VAC, 3-pole, manual-reset thermostat with a trip point of 572 º F (300 º C). The thermostat interrupts power to the main convection heater in the event of an abnormal condition.

  • Page 51: Relay - K7 Magnetron Cooling Fan

    Relay - K7 Magnetron Cooling Fan The K7 relay is a 240 VAC, 30 amp, double-pole, double-throw, 24 VDC relay coil. It switches power to the magnetron cooling fans when the magnetron filaments are actuated. Power is switched off after 4 minutes, 15 seconds.

  • Page 52: Catalytic Converter

    Vent Catalyst In addition to the main catalytic converter, the i5 oven contains an additional catalyst in the vent tube path. This catalyst further assists in the breakdown of grease and particulate matter before the excess air enters the atmosphere.

  • Page 53: Troubleshooting

    Troubleshooting...

  • Page 54: Overview Of Troubleshooting

    Overview of Troubleshooting This section contains information on the following: - Fault code descriptions - Fault code troubleshooting - Non-fault code troubleshooting For information on accessing TEST MODE 15. For information and illustrations on replacing components, see the appendix. Fault Code Descriptions For instructions on viewing the fault counter, see page 13.
  • Page 55 TROUBLESHOOTING F7: RTD Open This fault is displayed when the control detects that the RTD is “open.” The display will show a reading of “999 º F/C,” indicating the RTD is open. The fault is cleared when the control detects continuity.

  • Page 56: Fault Code Troubleshooting

    Fault Code Troubleshooting From , you can run oven diagnostics and check fault counts. To access TEST MODE Diagnostic mode, see page 15. F1: BLOWER (Blower Running Status Bad) Is the wiring harness properly connected? Check the motor controller, top and bottom blower motors, and I/O control board.
  • Page 57 TROUBLESHOOTING Reset and determine why it tripped – excess grease buildup, etc. (Figure 31, page 34) Is the RTD functioning properly? Replace the I/O control board (page A-8). Troubleshooting: F2: LOW TMP (Cook Temperature Low) Is the high-limit thermostat tripped? Is wiring from the solid state relay to the I/O control board OK?
  • Page 58 Is control board Intl. detecting 10A or more current? Test for 24 VDC on pin Replace the 2 of J7 connector control board. (page 51). See page A-8. Is amperage present at the current transformer even if the control board is not detecting it? Run test cook cycles to see if fault...
  • Page 59 TROUBLESHOOTING Are the switches open- ing in the correct sequence (P, S, M)? To access or for TEST MODE info on status indicators, see page 15. Are the switches closing in the correct sequence (M, S, P)? Verify wiring. If neces- sary, replace the cooling fans (see pages A-7 through A-8).
  • Page 60 F6: EC TEMP (Electrical Compartment Temperature High) Is the oven in an area of moderate temperature (120ºF (49ºC) or cooler)? Does the oven have room to ventilate? Required clearances: Top: 16” (406 mm) Sides: 2” (51 mm) Are both cooling fans rotating? Check for obstructions in...
  • Page 61 TROUBLESHOOTING Is the high-limit thermostat tripped? Reset (page 34) and determine why it tripped – excess grease buildup, etc. Troubleshooting: F8: HEAT LOW Are both blower motors moving air? Check in - see page 15. TEST MODE Is the heater defective? Check in - see page 15.
  • Page 62 Non-Fault Code Troubleshooting This section provides troubleshooting tips for issues that may occur independently of an oven fault. Is the keypad cable properly connected to the control board? Replace the keypad (page A-5 through A-6). If the problem persists, replace the control board (page A-8).
  • Page 63 TROUBLESHOOTING Is wiring from the control board to the display OK? Is pin 1 on the J7 connector receiving 5 VDC? (see schematic, page 51) Replace the display (page A-8). Troubleshooting: No Display – Screen is Blank Does the keypad beep when a key is pressed? Replace the fuses.
  • Page 64 Are there any fault Troubleshoot the codes present? See page fault(s) using the steps on pages 37-44. Is the menu part number and revision correct? Verify with customer or contact TurboChef Customer Service. Contact Customer Service to obtain the correct menu and load it to the oven.
  • Page 65 TROUBLESHOOTING Smart Card Does a backup copy of the menu work? Is the connection from smart card reader to control board OK? Ensure the cable connecting the reader to the control board is securely attached and not damaged. Replace the card reader (page A-8).
  • Page 66 “Write Fail” Message When Loading Menu Smart Card Try writing to a new smart card. Was the write successful? Is the connection from smart card reader to control board OK? Ensure the cable connecting the reader to the control board is securely attached and not damaged.

  • Page 67: Plugged In Or Restarted

    TROUBLESHOOTING Unplug the oven and then plug it back in. Did this fix the problem? Check for microwave leakage (page 27). If no leakage is found, replace the control board (page A-8). Troubleshooting: “Defective Media” Message When Oven is Plugged in or Restarted Does the message prevent the oven from reaching the “Oven Off/ Cooling Down”...

  • Page 68: Oven Schematic

    Oven Schematic...
  • Page 69 EMI FILTER MW2 CT AYA6A 380-415, 3Ø 230VAC, 3Ø 5 WIRE INPUT 4 WIRE INPUT GRAY Figure 34: i5 Oven Schematic K8 (STIRRER) 120°F (49°C) B-16 K7 (FANS) NOTE: ALL 50 HZ OVENS HAVE 230VAC TRANSFORMERS( TAPS 1-2 ARE CONNECTED) SPEAKER...
  • Page 70 This page intentionally left blank.

  • Page 71: Appendix - Replacing Oven Components

    Appendix - Replacing Oven Components...

  • Page 72: Comprehensive Table Of Oven Components

    Replacing a component while the oven is plugged in can result in serious injury or death. NOTE: For hardware, see the illustrations contained in this appendix. To Replace This... Item Part Number Blower Motor (Bottom) I5-9042 Blower Motor (Top) I5-9040 Blower Wheel (Bottom) 103550 Blower Wheel (Top)
  • Page 73 Hinge, Guide, Switch Slide, Upper Hinge, Gusset, LHS Hinge, Gusset, RHS Hinge Module, Base Hinge, Torsion Bar Hinge, Weldment, Countrblnce Bracket, LHS I5-9326 Hinge, Weldment, Countrblnce Bracket, RHS I5-9327 Interlock Switch (Monitor) Interlock Switch (Primary) Interlock Switch (Secondary) Jetplate (Bottom)

  • Page 74: Replacing Items - No Cover Removal Required

    Thermostat, Magnetron (Left)* 102070 Thermostat, Magnetron (Right)* 102070 Transformer, Filament NGC-3061-1 Transformer, High-Voltage NGC-3062-1 Vent Catalyst Foil Pack RWD-9191 Vent Tube Cover I5-9209 Voltage Sensor 100783 Waveguide (Left)* I5-9330 Waveguide (Right)* I5-9330 Waveguide Gasket (Left)* I5-9331 Waveguide Gasket (Right)* I5-9331...
  • Page 75 Stirrer Vent Catalyst Foil Pack Vent Tube Cover Weldment, Heat Chnl, Vent Tube NGC-1397 Figure A-1: No Cover Removal Required Item Part Number Hardware Description I5-9203 None i5-9246 None I5-9168 None I5-9165 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH I5-9307 Screw, 6-32 x .38, PFH, 100 Deg, SS...

  • Page 76: Replacing Items - Opening Top Cover Required

    Figure A-3: Opening Top Cover Required Replacing Items - Opening Top Cover Required (Figure A-3) DANGER: Before replacing any oven component, ensure the oven is removed from any power source. Replacing a component while the oven is plugged in can result in serious injury or death. CAUTION: Before removing/installing any component, make sure it is disconnected from the wire harness (where applicable).
  • Page 77 Relay Bracket Relay, Solid State (K4/K5 - Heaters) 101286 * NOTE: Additional keypad detail on Figure A-6, page A-8. Item Part Number Hardware Description I5-9243 Screw, #10-32 x 3/8 lg, PFLH, 100 Deg, SS 101401 (qty 2) 100592 None 100592...

  • Page 78: Replacing Items - Removing Top Cover Required

    Replacing Items - Removing Top Cover Required (Figures A-4, A-5, A-6) DANGER: Before replacing any oven component, ensure the oven is removed from any power source. Replacing a component while the oven is plugged in can result in serious injury or death. CAUTION: Before removing/installing any component, make sure it is disconnected from the wire harness (where applicable).
  • Page 79 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH A) Screw, #10-32 x 2 1/4, PPH, SS 100083 B) Washer, Lock, #10 Int Tooth, Cres I5-9263 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH 100481 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH...

  • Page 80: Replacing Items - Removing Left Side Cover Required

    Power Cord Voltage Sensor * NOTE: For more interlock switch detail, see Figure A-11, page A-13. Item Part Number Hardware Description I5-9040 Nut, 1/4 - 20, Serr Hex Flange, Plated I5-9042 Nut, 1/4 - 20, Serr Hex Flange, Plated 103551...
  • Page 81 A-10 APPENDIX - REPLACING OVEN COMPONENTS Figure A-7: Removing Left Side Cover Required Figure A-8: Blower Motor Assembly...

  • Page 82: Replacing Items - Removing Right Side Cover Required

    Interlock Switch - Secondary* Mounting Bracket, Interlock Switch* RTD, Cook Cavity * NOTE: For more interlock switch detail, see Figure A-11, page A-13. Item Part Number Hardware Description I5-9066 None I5-9302 Screw, #8, Serr PPHD, Truss, Black Oxide I5-9284 Screw, Sh Mtl #8 x 1/2, Serrated PHTRH...

  • Page 83: Replacing Items - Removing/Opening Multiple Covers Required

    Hinge, Guide, Switch Slide, Lower Hinge, Guide, Switch Slide, Upper Hinge, Gusset, LHS Hinge, Gusset, RHS Hinge Module, Base Hinge, Torsion Bar Hinge, Weldmt, Ctrblnce Brkt, LHS I5-9326 Hinge, Weldmt, Ctrblnce Brkt, RHS I5-9327 Magnetron (Left) Magnetron (Right) Thermostat, Magnetron (Left) Thermostat, Magnetron (Right)
  • Page 84 A-13 17 19 18 20 Figure A-10: Removing/Opening Multiple Covers Required Figure A-11: Counter Balance Assembly, Hinge, and Switch Detail...
  • Page 85 O U T S I D E N O RT H A M E R I C A C A L L +1 214-379-6000 or Your Authorized Distributor Accelerating the World of Cooking Part Number: i5-9231/Revision B/March 2008 Country Code: NA/EU T U R B O...

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