TurboChef i3 Service Manual
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TurboChef i3 Service Manual

Rapid cook oven
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Service Manual
i3
F O R T H E T U R B O C H E F
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R A P I D C O O K O V E N
© 2009-2010 TurboChef Technologies, Inc.

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Summary of Contents for TurboChef i3

  • Page 1 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 © 2009-2010 TurboChef Technologies, Inc.
  • Page 3 For further information, call 1-800-90TURBO +1 214-379-6000...
  • Page 4 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. Please carefully read this manual and retain it for future reference. ©2009-2010 TurboChef Technologies, Inc.

  • Page 5: Table Of Contents

    Table of Contents Important 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 Options Screen Setting the Language Setting the Date/Time Adjusting the Volume Setting the F2 Alarm Making a Copy of the Oven Menu Updating the Oven Menu Updating the Oven Firmware Resetting the Oven Test Mode - Testing Oven Parts Top and Bottom Blower Heaters Magnetron Test Stirrer...
  • Page 7 Convection System Troubleshooting Oven Door Removing/Reinstalling the Oven Door Adjusting the Oven Door Interlock Switches Adjusting the Door Switches Hinges and Counter-Balance Assembly Adjusting the Counter-Balance Assembly Measuring RF Leakage for Microwave Safety Oven Door Troubleshooting Microwave System Capacitors Testing a Capacitor Filament Transformers Wiring the Filament Transformers High-Voltage Transformers...
  • Page 8 Smart Card Reader Solid State Relay - K4/K5 Heater Speaker USB Port Wire Harness Voltage Sensor Control System Troubleshooting Filtering System Catalytic Converter Drain Pan Air Filter Vent Catalyst Filtering System Troubleshooting 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...

  • Page 9: Important Safety Instructions

    IMPORTANT SAFETY INSTRUCTIONS WARNING: When operating this oven, 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.

  • Page 10: Grounding Instructions

    Refer to pages 25-26 for leakage test procedures. RF Interference Considerations The i3 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.

  • Page 11: Specifications And Installation

    Specifications and Installation...

  • Page 13: Theory Of Operation

    Volume: 1.14 ft (32.3 liters) troubleshooting, installing, cleaning, and operating Clearances the i3 oven. If you have questions that are not Top: 19” (483 mm) addressed in this manual, contact Technical Service Sides: 2” (51 mm) (800.90TURBO, +1 214-379-6000) or your Authorized Distributor.

  • Page 14: Electrical Specifications

    SPECIFICATIONS AND INSTALLATION Electrical Specifications TurboChef recommends a Type D circuit breaker for all installations outside the US. Single Phase i3 US model (i3-9500-1)* i3 UK model (i3-9500-2-UK) 208/240 VAC, 60 Hz, 40 amps 230 VAC, 50 Hz, 40 amps...

  • Page 15: Unpacking Instructions

    TurboChef will not recognize a fallen oven as the top of the oven. a warrantable claim and is not liable for any...

  • Page 16: Installation Near Open Heat Source

    TurboChef Stacking Stand - Part Number: i5-9369 Ventilation Requirements - Height: 44.6” (1133 mm) The TurboChef model i3 oven has been approved by - Width: 32.5” (826 mm) Underwriter’s Laboratory for ventless operation (UL - Depth: 26.5” (673 mm) 710B, KNLZ listing) for all food items except for foods classified as “fatty raw proteins.”...
  • Page 17 Counter Top / Table Partition 21.25” (540 mm) Partition Above Counter Top 21.25” (540 mm) Above Counter Top TurboChef Grill i3 Oven Deep Fryer 12” 6” (152 mm) (305 mm) Minimum Minimum Figure 4: Installation Near Open Heat Source 21.25” (540 mm) 4.5”...
  • Page 18 SPECIFICATIONS AND INSTALLATION This page intentionally left blank.

  • Page 19: Daily Maintenance

    Daily Maintenance...
  • Page 21 Daily Maintenance Supplies and Equipment - Oven Cleaner (Part Number: 103180) The following steps will help maintain your i3 oven. Use only TurboChef Oven Cleaner and Oven Guard. - Oven Guard (Part Number: 103181) The use of any other cleaning products can damage...
  • Page 22 - Rinse the oven interior with clean water. - Thoroughly dry the oven interior with a clean towel. Step 9: Apply TurboChef Oven Guard - Spray Oven Guard onto a clean towel. - Wipe the oven’s interior walls and the inside of the oven door.

  • Page 23: Oven Controls And Cooking

    Oven Controls and Cooking...

  • Page 25: Oven Controls

    A B C D E F G H I J K L M N O BACK E N TE R S TO P P Q R S T U V W X Y Z BACK EN T ER STOP Figure 6: Oven Controls Oven Controls 6.

  • Page 26: Cooking

    Step 1: Turn the Oven On When the oven is off (Figure 7), the oven temperature has receded below 150°F (66°C), but the display and keypad remain on. TURBOCHEF i3 OVEN OFF READY TO CLEAN Press the On/Off key to turn the oven on.

  • Page 27: Step 4: Soaking

    Step 4: Soaking Once the oven temperature reaches the set point, the oven will continue to warm for eight minutes to ensure the cook cavity surfaces absorb enough heat so as to not affect cooking results. This process is called “soaking.” Step 5: Ready to Cook or “Idle”...

  • Page 28: Step 8: Remove Food From Oven

    OVEN CONTROLS AND COOKING Step 8: Remove Food from Oven WARNING: Dish and inside of oven/oven door are hot! COOKING DONE Open the oven door and check/remove food. PLEASE REMOVE FOOD FROM OVEN Figure 12: Cooking Done Step 9: Additional Cooking Options The “Additional Cooking Options”...

  • Page 29: Info Mode

    Info Mode Test Mode Edit Mode...

  • Page 31: Overview Of The Info Mode

    (Figure 18), press the - Access service phone numbers soft key adjacent to the fault code. FAULT LOG F1: BLOWER F6: EC OT S/N: i3-DXXXXXX COUNTS SCROLL SOFTWARE VERSION VAC = 240 F2: LOW TEMP F7: RTD OPEN...

  • Page 32: Viewing The Service Numbers

    INFO MODE - DHCP (TurboChef use only) press the L5 soft key to adjust the beeper volume. - Oven Type: Ensure this option is set to “i3.” Setting the F2 Alarm Setting the Language Under normal operation, the F2 alarm will terminate NOTE: Not available on some oven models.

  • Page 33: Making A Copy Of The Oven Menu

    5. When the oven restarts and the display turns on, the update is complete. Remove the smart card. 6. Verify the oven type is set to “i3” (Figure 19). NOTE: If the update is unsuccessful, the display will Smart Card...

  • Page 34: Test Mode - Testing Oven Parts

    TEST MODE Test Mode - Testing Oven Parts Status Indicators From screen 2 of the (Figure 16, page 13), Figure 22. The status indicators are located at the INFO MODE press the L1 soft key to access (Figure 22). bottom of the screen, and consist of: TEST MODE TEST MODE...

  • Page 35: Manufacturing Mode

    Manufacturing Mode Burn-In Press the L3 soft key (Figure 23) to initiate a 25- Press the R3 soft key (Figure 22, page 16) to place the minute burn-in. This feature helps ensure all cavity oven in (Figure 23). When in MANUFACTURING MODE walls reach thermal equilibrium before testing is , the following tests and...

  • Page 36: Volt On

    TEST MODE Volt On This setting should not be changed in the field unless instructed by TurboChef. Press the R2 soft key (Figure 23, page 17) to enable/disable the voltage from displaying in . Typically, this setting is INFO MODE disabled for ovens installed outside the United States.

  • Page 37: Edit Mode

    Overview of the Edit Mode Changing Set Temperatures serves three main purposes: The i3 oven can store two set temperatures. Think of EDIT MODE 1. To edit set temperatures. each temperature as a “block” of 10 food groups with 2. To edit names of food groups and recipes.

  • Page 38: Changing Food Group/Item Name

    EDIT MODE Changing Food Group/Item Name Changing Recipe Settings To change a food group or item name, To access the Recipe Edit screen, follow the steps in 1. Place the oven in (see page 19). the adjacent section titled Changing Food Group/Item EDIT MODE 2.

  • Page 39: Oven Systems

    Oven Systems...

  • Page 41: Convection System

    Its top speed is 7100 RPM at 1 HP. The bottom blower motor is controlled by The i3 utilizes two versions of the top jetplate. Ovens a proprietary controller and spins clockwise. with serial numbers between 00001 and 01000 use a ceramic top jetplate.

  • Page 42: Stirrer Motor And Assembly

    150°F (66°C). The oven door assembly consists of a shunt plate, skin, and handle. Each of these items can be The i3 utilizes two versions of the stirrer and the replaced independently. stirrer shaft. Ovens with serial numbers between 00001 and 01000 use a mica stirrer, whereas ovens...
  • Page 43 CAUTION: This procedure should be 7. Reinstall the door switches. performed while oven is hot. To avoid burns, 8. With the door closed, set the left side switch be careful when adjusting the oven door. (primary) so the paddle is closed but not 1.

  • Page 44: Interlock Switches

    OVEN SYSTEMS Interlock Switches Hinges and Counter-Balance Assembly The primary, secondary, and monitor interlock The door hinges and counter-balance assembly ensure switches engage and disengage in sequence to ensure the door consistently opens and closes smoothly. The a proper seal. When the door is opened, the switch counter-balance assembly also allows the door to sequence is P, S, M.

  • Page 45: Measuring Rf Leakage For Microwave Safety

    Step 6: Top of gauge should be flush against the top of the bracket. Step 7 = Tighten Step 8 = Loosen Slightly 3-32” Step 5 Step 6: Screw fits all the way Step 4 into the notch. Step 4 Step 5 NOTE: Oven door and chassis removed for clarity.

  • Page 46: Oven Door Troubleshooting

    OVEN SYSTEMS 4. Place a water load into the cook cavity. The water NOTE: There may be several places on the door that load must conform to the following require this procedure. If so, start out with a fresh specifications: water load each time a new area is measured, or if - Volume: 275 ml ±...

  • Page 47: Microwave System

    5. Check for an open or shorted capacitor by placing ohmmeter leads between the capacitor terminals: The i3 oven employs left and right microwave sys- - Rising/escalating ohm readings = capacitor OK tems. In the case of an over-current situation, the F3 - Constant infinite resistance = capacitor open fuse will blow, shutting off both systems immediately.

  • Page 48: High-Voltage Transformers

    OVEN SYSTEMS NOTE: The terminals with the orange wire always go The wiring issue must be corrected prior to returning to Terminal 3 on US models. the oven to service, as the voltages must be: : 208 VAC between 1 & 2 and NORTH AMERICA To verify correct wiring (International), measure the 240 between 1 &...

  • Page 49: Testing A High-Voltage Diode

    High Voltage Transformer Part Primary Voltage, Frequency, Taps, Secondary Taps and Resistance Numbers and Resistance NGC-3062-1 208 VAC, 60 Hz, 1 & 2, 4, Ground, 53.60–65.52 0.819–1.001 240 VAC, 60 Hz, 1 & 3, 0.972–1.188 NGC-3062-2 230 VAC, 50 Hz, 1 & 2, 3, Ground, 57.52–70.30 0.972–1.188 NGC-3062-3...

  • Page 50: Magnetrons

    150°F (66°C). FILAMENT AND HIGH VOLTAGE The i3 utilizes two versions of the stirrer and the TERMINALS stirrer shaft. Ovens with serial numbers between 00001 and 01000 use a mica stirrer, whereas ovens with a serial number of 01001 or greater use a metal stirrer.

  • Page 51: Control System

    Control System Electrical Compartment Cooling Fan Thermostat This section contains information about the The cooling fan thermostat actuates the rear cooling following components: fans when the electrical compartment temperature - Control board reaches 120 º F (49 º C). - Display - Electrical compartment cooling fans - Electrical compartment cooling fan thermostat Electrical Compartment Thermocouple...

  • Page 52: High-Limit Thermostat

    OVEN SYSTEMS High Limit Thermostat Magnetron Thermostats The high limit thermostat is a three-pole, manual-reset The magnetron thermostats are “open-on rise.” They are thermostat with a trip point of 572 º F (300 º C). The designed to open at 212 º F (100 º C), which triggers an thermostat interrupts power to the main convection F5 fault.

  • Page 53: Relay - K7 Magnetron Cooling Fan

    Relay - K7 Magnetron Cooling Fan Smart Card Reader The K7 relay is a 240 VAC, 24 VDC coil, 20-amp, The smart card reader allows the oven operator to load sealed single-pole relay. It switches power to the mag- menu or firmware updates from a smart card. An netron cooling fan when the magnetron filaments are oven’s menu can also be saved to a smart card.

  • Page 54: Voltage Sensor

    This section contains information about the following components: Vent Catalyst - Catalytic converter In addition to the main catalytic converter, the i3 oven - Drain pan contains a catalyst in the vent tube path. This catalyst - Air filter further assists in the breakdown of grease and particu- - Vent catalyst late matter before the excess air enters the atmosphere.

  • Page 55: Troubleshooting

    Troubleshooting...

  • Page 57: Overview Of Troubleshooting

    Overview of Troubleshooting NOTE: The F2 alarm can be turned off to prevent the cook cycle from being interrupted. See page 14 for This section contains information on the details. following: - Fault code descriptions F3: Magnetron Current Low - Fault code troubleshooting This fault is displayed when the current transformer - Non-fault code troubleshooting (CT) on the I/O control board detects less than 10...
  • Page 58 TROUBLESHOOTING F7: RTD Open F8: Heat Low This fault is displayed when the control detects that This fault displays during WARMING UP TEST MODE the RTD is “open” for more than two continuous if the cook cavity temperature fails to rise at least 14 º...

  • Page 59: Fault Code Troubleshooting

    Fault Code Troubleshooting From , you can run oven diagnostics and check fault counts. To access or turn on TEST MODE TEST MODE Diagnostic mode, see page 16. For illustrations on removing/replacing oven components, see the appendix at the end of this manual. Troubleshooting: F1: BLOWER (Blower Running Status Bad) Do resistance measurements...
  • Page 60 TROUBLESHOOTING Troubleshooting: F2: LOW TMP (Cook Temperature Low) Is either of the heater ele- Reset (Figure 36, page 32) Is the high-limit ments defective? (heaters and determine why it thermostat tripped? should have a resistance of tripped – excess grease 14.4 Ohms) buildup, etc.
  • Page 61 Troubleshooting: F3: MAG CURR (Magnetron Current Low) Is the K6 mechanical Energize the mag- relay in good working Intl. U.S. netron circuit from Is the oven International or U.S.? order? Test Mode (page 16). Are there 10+ amps present on the current Replace the F3 fuse and Confirm the F3 fuse is a Replace K6...
  • Page 62 TROUBLESHOOTING Troubleshooting: F4: MONITOR (Door Monitor Defective) Is the F3 fuse blown? Replace the F3 fuse. Are the switches open- ing in the correct sequence (P, S, M)? To Adjust the door switches. See page 24 access or for TEST MODE for instructions.
  • Page 63 Troubleshooting: F6: EC TEMP (Electrical Compartment Temperature High) Is the oven in an area of moderate temperature (120ºF (49ºC) or cooler)? Does the oven have Relocate oven to room to ventilate? cooler area. Move oven to open area or remove See page 1 for standard items that are in close proximity.
  • Page 64 TROUBLESHOOTING Troubleshooting: F8: HEAT LOW Are both blower motors moving air? Check in - see page 16. TEST MODE Is the high-limit Is the heater defective? Check in See page 37 thermostat tripped? - see page 16. TEST MODE to troubleshoot F1: BLOWER (Blower Running Status Bad)
  • Page 65 Non-Fault Code Troubleshooting This section provides troubleshooting tips for issues that may occur independently of an oven fault. Troubleshooting: No Keypad Input Is the keypad cable properly connected to the control board? Correct wiring. Replace the keypad. If the problem persists, replace the control board.
  • Page 66 TROUBLESHOOTING Troubleshooting: No Display – Screen is Blank Does the keypad beep when a key is pressed? Is the power supply receiving power? Replace the fuses or correct wiring. Is wiring from the Correct wiring. If ribbon control board to the cable is damaged, replace display OK? the keypad.
  • Page 67 Verify with fault(s) using the steps (e.g., frozen, fresh, etc.)? customer or contact on pages 35-42. TurboChef Customer Service. Ensure the food item is being properly Is the correct amount Contact TurboChef stored/prepared of food (portion) Customer Service to before cooking.
  • Page 68 (menudata.bin) No backup copy the menu work? and in the correct location (TC_Menus)? If the menu card was created by TurboChef, obtain a new menu card by contacting customer service at 800.90 or +1 214-379-6000. TURBO Is the connection from...
  • Page 69 Troubleshooting: “Write Fail” Message When Loading Menu Are you trying to write to a smart Smart Card USB Device card or USB device? Is the USB device Try writing to a new securely attached to the smart card. Was the oven? write successful? Is the connection from...

  • Page 70: Plugged In Or Restarted

    TROUBLESHOOTING Troubleshooting: “Defective Media” Message When Oven is Plugged in or Restarted Does the message prevent the oven from reaching the “Oven Off/ Cooling Down” screen? Unplug the oven and Operate the oven as then plug it back in. you would normally. Did this fix the problem? Check for microwave...

  • Page 71: Oven Schematic

    Oven Schematic...
  • Page 73 230VAC 208/240VAC 9/15/09 GREG HAUN 380-415VAC 60HZ 50HZ 60HZ 50HZ C-22 SCHEMATIC, i3 50HZ B-17 MULTIPHASE, 230, 380-415 VAC, 50 HZ C-21 MULTIPHASE, 208 - 240 VAC, 60 HZ i3-9500 i3-9100 NEMA 15-30P NEMA 6-50P Figure 38: i3 Oven Schematic...
  • Page 74 This page intentionally left blank.

  • Page 75: Appendix - Replacing Oven Components

    Appendix - Replacing Oven Components...

  • Page 77: Replacing Oven Components

    - Removing Right Side Cover Required (page A-10) - Removing Left and Right Side Covers Required (page A-11) If you have any questions that are not addressed in this manual or appendix, please contact TurboChef Customer Service at 800-90TURBO or +1 214-379-6000.
  • Page 78 The i3 utilizes two versions of the top jetplate. Ovens with serial numbers between 00001 and 01000 use the ceramic top jetplate. All i3 ovens with serial number 01001 and greater use the metal top jetplate that includes the glass jetplate insert.
  • Page 79 NOTE: The installation of items 10, 11, 12, 16, and 17 will vary based on the oven’s serial number. See the parts list on page A-2 for more information. NOTE: Item 14 attached to bottom jetplate upon installation. Figure A-1: No Cover Removal Required Figure A-2: Door Assembly Detail...

  • Page 80: Opening Top Cover Required

    Hardware Description Hardware Part Number(s) Reference # Capacitor and Diode, Monitor Relay i5-9390 None None Cover, Top i3-9243 Screw, #10-32 x 3/8 lg, PFLH, 100 Deg, SS 101401 (qty 2) Fuse, F1, 12-amp 100592 None None Fuse, F2, 12-amp 100592...

  • Page 81: Removing Top Cover Required

    Figure A-3: Opening Top Cover Required Removing Top Cover Required (Figures A-4, A-5, A-6) DANGER: Before replacing any microwave circuit component, ensure the oven is removed from power source. Replacing a component while the oven is in operation can result in serious injury or death.
  • Page 82 None Waveguide Gasket (Right) i5-9331 None None The i3 utilizes two versions of the stirrer shaft. Ovens with serial numbers between 00001 and 01000 must use i5-9151. All i3 ovens with a serial number of 01001 or greater use i3-9151.
  • Page 83 REF: Heat Shield REF: Cooling Fan Thermostat Figure A-4: Removing Top Cover Required Figure A-5: Stirrer Motor and Assembly Detail REF: Keypad Figure A-6: Top Cover Detail...

  • Page 84: Removing Left Side Cover Required

    100906 (qty 4) Blower Wheel (top) 104107 None None Blower Wheel (bottom) 104108 None None Cover, Left Side i3-9301 Screw, #8 Serr, PHD Truss, Black Oxide 101691 (qty 5) Heat Slinger 102708 None None Helper Spring, Interlock Switch* i5-9397 None...
  • Page 85 REF: EMI Filter, Bracket, and Cover Figure A-7: Removing Left Side Cover Required Figure A-8: Blower Motor Assembly...
  • Page 86 Figure A-9: Removing Right Side Cover Required Figure Item Description Item Part Number Hardware Description Hardware Part Number(s) Reference # Catalytic Converter i3-9066 None None Cover, Right Side i3-9302 Screw, #8, Serr PPHD, Truss, Black Oxide 101691 (qty 5) Heater Assembly...

  • Page 87: Removing Right And Left Covers Required

    Nut, 1/4 - 20, Serr, Hex Flange, Plated Steel 100906 (qty 2) Hinge, Gusset, RHS i5-9179 Nut, 1/4 - 20, Serr, Hex Flange, Plated Steel 100906 (qty 2) Hinge Module, Base i3-9193 None None Hinge, Torsion Bar i3-9144 Spacer, Adjustment Call TurboChef...
  • Page 88 4 240 International Pkwy, Suite 105 Carrollton, Texas 75 007 U S A + 1 214 -3 79-60 00 P H O N E + 1 214 -3 79-60 73 Part Number: i3-9231 / Revision B / April 2010 FA X Country Code: NA/EU turbochef.com...

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