TurboChef Service Manual FOR THE TURBOCHEF NGC (TORNADO) OVEN Accelerating the World of Cooking 800.
For further information call: 800.90 T U R B O + 1 214.379.
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.
Table of Contents Important Safety Instructions General Safety Information Reducing Fire Risk Precautions to be Observed Before and During Servicing to Avoid Possible Exposure to Excessive Microwave Energy Grounding Instructions Power Cord Replacement RF Interference Considerations i i i ii ii ii ii Chapter 1: Installation, Specifications and Maintenance Specs and Dimensions Dimensions Construction Standard Features Certifications Packaging Power Supply (Domestic and Intl Electrical Specifications) Power
Oven Options User Configurable Options - Enable/Disable Codes User Configurable Options - Access Codes Control System Panel Parts Control System Troubleshooting 18 19 19 20 21 Chapter 5: The Microwave System Voltage Doubler Circuit Description Monitor Circuit Description Voltage Doubler Theory of Operation Microwave System Parts Microwave System Components Wave Guide Cover Replacement Wave Guide/Wave Guide Cover Parts Wave Guide Replacement High Voltage and Filament Transformer Replacement Wiring the High
Chapter 7: The Convection Circuit Convection Circuit Components Convection Circuit/Blower Motor Parts Convection Circuit Troubleshooting Motor Winding Resistances Table 47 48 49 50 Chapter 8: IR Element and Catalytic Converter Components IR Element and Catalyst Removal Removing the IR Element Removing & Installing the Catalytic Converter Installing a New IR Element IR Element and Catalytic Converter Parts 51 51 51 52 52 52 Chapter 9: Schematics and Schematic Components Schematic Parts Line Voltage Compo
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 x x x x x x x x x Read all instructions before using the appliance. Install or locate this appliance only in accordance with the provided installation 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.
Installation, Specifications, and Maintenance
INSTALLATION, SPECIFICATIONS, AND MAINTENANCE FIGURE 1 1 : NGC (Tornado) Dimensions SPECS AND DIMENSIONS Dimensions Height with legs Width Depth with handle Weight EXTERIOR COOK CAVITY 19” (483 mm) 23” (584 mm) 26” (660 mm) 25.7” (653 mm) 28.2” (716 mm) 190 lbs. (86 kg) 8” (203 mm) 15.5” (394 mm) 14.7” (373 mm) WALL CLEARANCE Back Sides 0” (0 mm) unless built-in (page 2) 2” (51 mm) (minimum) 31.5” (800 mm) 28.
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, 5wire (3L + N + Ground) Circuit Breaker: Type D, min.
INSTALLATION, SPECIFICATIONS, AND MAINTENANCE (102 mm) FIGURE 2 : Built-in Installation Specs FIGURE 3 : Open Heat Source Installation Specs 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.
4 INSTALLATION, SPECIFICATIONS, AND MAINTENANCE Oven Restraint Kit (TC3-0242 KIT) The Oven Restraint Kit is an optional system that helps prevent the oven from moving forward during use and/or cleaning. It will not prevent the oven from falling off a countertop if the legs are allowed to slide off the edge or if the oven is intentionally or forcefully pulled off. Proper installation instructions are included with the kit. for additional information, please call customer service at 800.90TURBO / +1 214.
INSTALLATION, SPECIFICATIONS, AND MAINTENANCE 1 6 2 3 4 5 7 8 9 10 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.
Theory of Operation
THEORY OF OPERATION THEORY OF OPERATION The TurboChef NGC (Tornado) oven utilizes three independent heat transfer mechanisms to rapidly cook food. Should a problem arise with any of the components listed below, please turn to the appropriate section within this manual for further instructions. The systems are as follows: Convection Infrared energy Microwave energy For the purpose of this manual, each independent heat transfer mechanism is individually identified.
8 THEORY OF OPERATION GLOSSARY OF COMMON OPERATING TERMS Off State All the oven’s control systems are off and the cook cavity temperature is below 150ºF (66ºC). Cool Down A subset of the OFF STATE. During COOL DOWN, the oven will circulate the main convection blower until the cook cavity temperature is below 150ºF (66ºC). Ready State The oven has successfully warmed to the predefined set temperature. At this point the oven control is ready to receive cook commands via the keypad.
THEORY OF OPERATION Keypad The primary interface for the operator. Display Displays all visual information to the operator. Self-Test (STEST) A special diagnostic function that tests all critical subsystems to determine their operational state. Recipe A set of user-defined Events that determine a cook cycle. Events A single operational element that is a part of a recipe. Each recipe may have up to six events depending on programming. Each event can be set between 0 and 100% of the total cook time.
Fault Codes
FAULT CODES 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. NGCVXXXX XXXXXX S/N XXXXXX 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.
12 FAULT CODES NOTE: Door interlock switches are in parallel. See OVEN SCHEMATICS, pages 55-63. The fault is monitored 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.” 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.
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. +24VDC K3 MECH RELAY + 24 VDC - + 24 VDC - + 24 VDC - (U.S.
14 THE CONTROL SYSTEM CONTROL SYSTEM COMPONENT DESCRIPTIONS 24 VDC Power Supply 24 VDC output at 40 watts. Supplies control voltage for I/O control board, 24 VDC mechanical relays, and solid state relays. K1 Mechanical Relay 240 VAC, 30 Amp, Double Pole, Double Throw, 24 VDC Relay Coil. Switches power to the magnetron filament transformers. K2 Mechanical Relay 240 VAC, 30 Amp, Double Pole, Double Throw, 24 VDC Relay Coil. Switches power to the magnetron high voltage transformers.
THE CONTROL SYSTEM TEST NGC XXXXX TEST NGC XXXXX CC 81 0F IR 500 0F CC 81 0F BLOWER HEATER FAULTS MGTRON COOKS F/C IR ELE ACCUM IR SI STEST DIAG P S M t h i A W FIGURE 8 : Accessing Test Mode FIGURE 9: Test Mode - Screen 1 IR 500 0F 0 ELEC P S M t h i A W FIGURE 10: Test Mode - Screen 2 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.
16 THE CONTROL SYSTEM 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 CONTROL SYSTEM GROUP A EDIT GROUPS GROUP A ITEM 1 GROUP E < GROUP 1 ITEM 1 ITEM 5 COUNT COOK TIME IR SETPT FIGURE GROUP B GROUP F ITEM 2 ITEM 6 GROUP C GROUP G ITEM 3 ITEM 7 GROUP D GROUP H ITEM 4 ITEM 8 1 1 : Select Group FIGURE 12: Select Recipe 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 confirm and advance to the next screen.
18 THE CONTROL SYSTEM Loading a Menu from a Smart Card OVEN OPTIONS 1. Ensure the oven is in the OVEN OFF/COOLING DOWN mode. 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). 2. Enable the LOAD MENU function (page 19). The oven will return to the Off screen. 3. Remove the lower access panel (Figure 14).
THE CONTROL SYSTEM USER CONFIGURABLE OPTIONS - ENABLE/DISABLE CODES The following codes enable and disable each function/screen listed. They do not take you to the function/screen. 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.
20 THE CONTROL SYSTEM 6 1 5 7 4 8 10 2 9 3 FIGURE 1 7 : Control System Panel Enclosure and Parts CONTROL SYSTEM PANEL PARTS Figure 17. 1. NGC-1040 NGC-1209 2. 102960 3. 100508 (Varies)* 4. NGC-3023 5. 101954 Cover, Keypad/Display, Std Cover, Keypad/Display, SBK Nut, 4-40, Stainless Smart Card, Blank Smart Card, Programmed* Display Svc Kit (includes Items 5, 6, and 7) Spacer, 1/2” Lg, Aluminum 6. 100193 7. 100184 8. NGC-1110-1 NGC-1110-2 NGC-1110-3 NGC-1110-4 9. 100506 10.
THE CONTROL SYSTEM CONTROL SYSTEM TROUBLESHOOTING ISSUE RESOLUTION No Display (Blank) 1. Verify power 208 VAC or 240 VAC is going to the oven correctly. If not, correct the voltage supply. 2. Control DOES NOT beep when any key on the keypad is pressed. Check power going to the 24VDC power supply. Supply must have 208 or 240 VAC across L and N terminals. If there is no voltage, replace F1 and F2 fuses. If the voltage is OK, verify output of power supply is 24 VDC.
22 THE CONTROL SYSTEM ISSUE RESOLUTION F1: Blower Running Status Bad 1. Status Indicator “A” is highlighted/backlit in TEST MODE. Verify 208 or 240 (USA) / 230 (Intl) / 200 (Japan) / 220 (Latin America) VAC is going to the motor controller via pins 2 and 3. 208/240/230 VAC is present: Verify control wiring from the motor controller and I/O control board, specifically low-voltage wire OR-9. If all wires are OK, then refer to page 50 for motor controller troubleshooting.
THE CONTROL SYSTEM ISSUE RESOLUTION F2: Cook Temperature Low 1. Verify the high-limit thermostat is not tripped. If high-limit is tripped, reset and allow the oven to warm up. If high-limit is not tripped, follow the instructions below. High-limit thermostat is not tripped. Place a small water load in a microwave/heat-resistant container (approx. 275 ml) in the oven and place the oven in TEST MODE. Press the MGTRON key to actuate the microwave.
The Microwave System
THE MICROWAVE SYSTEM If during normal operation any of the interlock switches open - such as when the oven door opens - the control will turn off the microwave. If the monitor switch opens before the primary or secondary switches (abnormal operation), the monitor switch de-energizes the monitor relay. When this occurs, a dead short is placed across L1 and L2.
26 THE MICROWAVE SYSTEM MAGNETRON VOLTAGE TRANSFORMER OUTPUT VOLTAGE +(B) 0 +(B) 0 +2400 V (A) (A) -(C) -2400 V -(C) 2400 VDC + - + 2400 2400 FIGURE Current Flow 4800 VDC + - CAPACITOR CHARGES ON POSITIVE VOLTAGE SWING 2400 VDC + - - Current Flow -4800 V CHARGED CAPACITOR PLUS TRANSFORMER ON NEGATIVE VOLTAGE SWING 1 9 : Voltage Doubler Circuit Theory of Operation VOLTAGE DOUBLER THEORY OF OPERATION MICROWAVE SYSTEM PARTS Figure 19 1.
THE MICROWAVE SYSTEM 11 12 FILAMENT AND HIGH VOLTAGE TERMINALS 14 13 15 16 25 FA 26 F 27 24 28 17 (ORG) 18 (BLK) COOLING FINS 19 23 22 21 20 15 ANTENNA FIGURE 2 0 : Microwave System Parts 13. 100481 High Voltage Diode (x2) 14.
28 THE MICROWAVE SYSTEM MICROWAVE SYSTEM COMPONENTS Below is a description of each component within the Microwave System. High Voltage Capacitors Capacitor rating is 0.91uF, 2500 VDC for USA, Mexico, Brazil, and S. Korea. Magnetron Magnetrons supply the RF energy at 2.45 GHz and begin to oscillate when they are supplied with approximately 4.1KVDC at approximately .350 mA. During operation each magnetron will output a nominal 1 kW of power. Capacitor rating is 1.
THE MICROWAVE SYSTEM 29 31 32 33 34 35 30 36 29 37 FIGURE 2 2 : Wave Guide Cover/Wave Guide Removal and Replacement To determine software type, 1. Make sure the oven is in the COOLING DOWN/OVEN OFF mode. 2. Simultaneously press the BACK and ENTER keys. 3. Enter code 9-4-2-8 (W-H-A-T) and press ENTER. 4. The top line on the screen will display the word TEST, followed by the software type (for example, V2SWY, or TRNADO).
30 THE MICROWAVE SYSTEM 4. Using acetone, clean the oven floor where the new wave guide cover will sit. 5. Apply a 1/8” diameter bead of high temperature RTV (included with Item 29) along the outside edge of the wave guide cover flanges. NOTE: It is important to use the correct high temperature RTV as supplied by TurboChef. 6. Place the new wave guide cover in place. Secure with the fourteen (14) screws provided with Item 29. 7. Wait 15 minutes for RTV to cure.
THE MICROWAVE SYSTEM high-voltage transformers are most likely wired inphase. As a last check, energize the Microwave System and verify the voltages between the taps on each high-voltage transformer. The wiring issue must be corrected prior to returning the oven to service, as the voltages must be: 208 VAC between 1 & 2 and 240 between 1 & 3.
32 THE MICROWAVE SYSTEM FA F FILAMENT AND HIGH VOLTAGE TERMINALS ANTENNA FIGURE 2 4 : High Voltage Diode 5. While holding the MGTRON soft key, move the survey meter around the outline of the oven door, keeping the tip of the meter in contact with and perpendicular to the oven door. Record the highest leakage. 6. Using the same procedure, measure the leakage with the oven door opened to the point just before the primary and secondary switches disengage. Record the highest leakage.
THE MICROWAVE SYSTEM How to Check a Capacitor 1. Disconnect the oven from the power source. 2. Fully discharge the capacitor. 3. Isolate the capacitor from the circuit. 4. Connect the ohmmeter between the capacitor terminals. The ohmmeter should momentarily indicate a low impedance and then slowly return to infinite resistance. 5. Reverse the ohmmeter leads and repeat Step 4. 6. Check each terminal to case. Infinite resistance (open) should be indicated.
34 THE MICROWAVE SYSTEM MICROWAVE SYSTEM TROUBLESHOOTING ISSUE Magnetron Troubleshooting Guidelines RESOLUTION WARNING: Never test the secondary voltages. Voltage on this side of the circuit is lethal, reaching up to 5000 volts! All tests performed on the components are done with the oven unplugged and the capacitors discharged. The capacitors in this oven utilize a device that will automatically discharge the voltage. WARNING: components.
THE MICROWAVE SYSTEM ISSUE F3: Magnetron Current Low (cont.) RESOLUTION WARNING: Never try to check the secondary voltages of the High Voltage Transformers. With the top cover removed, safe access to the three (if US oven)/two (if International oven) terminals on the top of the transformers is available. NORTH AMERICA hold the - Place the AC voltmeter across terminals 1+3. Press and soft key. Voltage present should be 240 +/- 10%. MGTRON - Place the AC voltmeter across terminals 1+2.
36 THE MICROWAVE SYSTEM ISSUE F3 Fuse Blown, cont. Mag 1 or Mag 2 Not Working or Food Not Cooking Evenly RESOLUTION c. Monitor circuit fault: Verify operation of all interlock switches. In addition, check the Fault Log. If the monitor switch opened prior to the primary and secondary, the control would have recorded the occurrence. See page 25 as well as Chapter 6 (Oven Door) for troubleshooting (see F4 MONITOR).
The Oven Door
THE OVEN DOOR The proper fit and adjustment of the oven door is essential for safe and reliable operation of the NGC (Tornado) oven. The oven door provides three primary functions: 1. To protect the operator from the hot convection airflow. 2. To protect the operator from exposure to microwave energy. 3. To actuate the interlock switches. REMOVING/REINSTALLING THE OVEN DOOR To remove or reinstall the oven door, follow the steps below. Refer to Figure 26. 1. Ensure the oven has cooled. 2.
38 THE OVEN DOOR ADJUSTING THE OVEN DOOR WARNING: Procedure should be done while oven is hot. As a result, exercise extreme caution when adjusting the door. 1. Open the oven door and remove the plastic caps. 2. Ensure that the 3 screws on each side of the door are tight. 3. Remove the control panel, two 11/32” nuts and wiring from I/O board. 4. Loosen the hex screws and close the door. 5. Tap the center of the door to allow door and frame to align properly. 6.
THE OVEN DOOR FIGURE 27: Mis-adjusted Oven Door 3. Open and close the door several times to ensure it closes smoothly and the door actuator (Item 47) clears the slot in the flange. Reference Figure 29. The actuator must not hang or rub the opening or flange. Carefully bend to clear opening. 4. While the oven door is closed, verify that the bottom of the toggle is 85º to the bottom of the frame (Figure 29). If not, use items 75 and 76 (page 42) to achieve proper angle. 5.
40 THE OVEN DOOR 50 49 APPLY HI-TEMP GREASE TO AREA 48 47 ADJUSTING THE MONITOR SWITCH - OLD SETUP The old switch assembly is identifiable by the monitor switch being located on the right hinge assembly. Also, the serial number of the oven will follow this formatting (X = variable digit/letter): NGC-XXXXX (North America) NGCXX-XXXXX (International) To adjust the switch, follow the steps below. 51 1. Ensure the oven door is adjusted. Refer to ING THE COOK DOOR on page 38. 52 ADJUST- 2.
THE OVEN DOOR 56 58 x2 62 55 2 61 57 60 54 53 59 FIGURE 63 1 64 3 0 : Door Switch Assembly and Parts - Old Switch Setup 68 65 66 x2 69 68 67 67 68 FIGURE REF 3 1 : Monitor Switch Adjustment and Assembly Old Switch Setup 41
42 THE OVEN DOOR 72 APPLY HI-TEMP GREASE TO AREA 71 70 2 73 74 FIGURE 1 75 3 76 3 2 : Primary Switch Adjustment and Parts New Switch Setup ADJUSTING THE PRIMARY INTERLOCK SWITCH NEW SWITCH SETUP PRIMARY SWITCH ADJUSTMENT AND PARTS 1. When the oven completes BURN IN (if required, see page 38), closely examine the latch toggle position using the door switch gauge (Item 75). Figure 32 70. 102809 Screw, #8-32 x 3/8” 100Þ CSK 71. 102921 Screw, #8-32 x 3/8” 72. 101555 Screw, #4-40 x 3/4” 73.
THE OVEN DOOR 78 x2 82 79 83 x2 81 77 80 82 80 81 82 FIGURE 3 3 : Secondary/Monitor Adjustment and Parts New Switch Setup FIGURE 34: Secondary/Monitor Switch Assembly New Switch Setup 1. Disconnect power to the unit. disengage in sequence. 9. Close the oven door and verify the M, S, and P engage in sequence. 2. Disconnect the 40-pin connector from the I/O board to allow maximum clearance. 10.Energize the Microwave System and open the door. 3. Using the 0.060” (1.
Figure 35 84. NGC-3067* NGC-3067-2* 85. NGC-3021 86. NGC-1061 87. 102750 NGC-1216 88. NGC-1076-2 89. NGC-1132 90. 102945 Door, NGC, Generic* Door, NGC, SBK* Kit, Shunt Plate Hinge Block Handle, Door, Generic Handle, Door, SBK Actuator, Door Shim, Door Latch Bolt, 1/4”-20 x 1.00 OVEN DOOR PARTS See Figure 35 above. For mis-adjustments, see Figures 27 and 28 on page 39. OVEN DOOR ASSEMBLY FIGURE * Includes items 85 - 101. 97. 101688 98. 102698 99. NGC-1155 100. 101293 101. NGC-1170 91. NGC-1138 92.
THE OVEN DOOR 14 8 1 4 5 15 13 16 9 4 1 5 8 12 13 15 11 10 3 2 6 7 12 9 11 10 14 17 SHUNT CAVITY/PLATE Tightening Sequence FIGURE 3 2 6 16 SHUNT ASSY/DOOR COVER Tightening Sequence 3 6 : Oven Door Assembly: Tightening Specs Critical Adjustment Notes (Figure 35) 1. Orient with the gasket seam at the bottom of the door assembly. Gasket should be straight with no twists or pinching. 2. Attach insulation (Item 94) to the inside of the door cover using aluminum tape (Item 98).
46 THE OVEN DOOR INTERLOCK SWITCH TROUBLESHOOTING ISSUE RESOLUTION “Cook Door Open” Message Determine which interlock switch is open. Access interlock switch status. TEST MODE to view 1. P S M - Primary and/or secondary interlock is open (old switch setup). P SM - Primary interlock is open (new switch setup). Verify action of the latch assembly and oven door. When the door closes, the actuator should freely clear the slot on the flange.
The Convection Circuit
THE CONVECTION CIRCUIT The Convection Circuit provides the high-temperature airflow required to brown and cook food items. CONVECTION CIRCUIT COMPONENTS The following is a description of each component within the Convection Circuit and how each acts within the circuit. Figure 37 below shows a block diagram of the Convection Circuit. Main Convection Heater The main convection heater is an open-coil style heater rated at 3300 watts at 208 VAC with a resistance of 13.11 Ohms.
THE CONVECTION CIRCUIT 48 1 109 x10 110 1 This Ope device ratio 1. This n complies is 2. This devi subject with device may to thePart 18 of rece ce mus not caus followingthe ived FCC und , inclut acce e harm cond Rule This esired ding pt any ful ope inte inte inte itions: s. DHHOven ratio rfere rfere rfere S Fedecomplies n. nce nce nce. that ral Perf with may orm app caus ance licab e Stan le sect To prov dard ions 21 CFR of shoc ide k, conncont 1030 inue .10.
THE CONVECTION CIRCUIT CONVECTION CIRCUIT TROUBLESHOOTING ISSUE RESOLUTION F8: Heat Low 1. Check that the blower motor is moving air. Blower motor is not moving air: Check blower motor assembly and verify motor is stalled. Unplug oven and correct obstruction or replace motor. (For access to motor shaft, remove top panel.) Blower motor is moving air: Verify high-limit thermostat is not tripped. See the high-limit thermostat information below.
50 THE CONVECTION CIRCUIT ISSUE RESOLUTION F1: Blower Running Status Bad 1. Verify motor spins freely. Motor seized: Unplug oven and correct obstruction or replace motor. Motor spins freely: Verify motor windings (see table below). 2. Verify motor windings are OK. Measure the resistance between windings and chassis. Unplug oven and replace motor if resistances do not agree with the values in the table below. If motor is OK, proceed to step 3, below. 3.
IR Element and Catalytic Converter
IR ELEMENT AND CATALYTIC CONVERTER The IR Element and Catalytic Converter provide two very different, but essential functions. The IR element provides the bottom browning similar to a residual broiler or salamander type cooking appliance - required for cooking most food items. The IR element temperature is independently controlled in each recipe. The catalytic converter scrubs the air to eliminate VOCs and grease particulates that are liberated during the cooking process.
52 IR ELEMENT AND CATALYTIC CONVERTER CAUTION: Do not allow the thermocouple lead wires to kink. They are solid wire and will break. Removing and Installing the Catalytic Converter 1. Unplug the oven. 2. Remove the IR element. (See above procedure.) 3. Once the IR element has been removed, remove the catalytic converter clip (Item 121) to access the catalytic converter. Figure 39.
Schematics and Schematic Components
SCHEMATIC COMPONENTS FIGURES 40 THRU 45: NGC OVEN SCHEMATICS Figure Figure Figure Figure Figure Figure 40 41 42 43 44 45 I/O Board Schematic NGC US Schematic NGC UK Schematic NGC EW Schematic NGC ED Schematic NGC Brazil Schematic SCHEMATIC PARTS Line Voltage Components Capacitor, High Voltage (C1) Capacitor, High Voltage (C2) Controller, Motor Diode, High Voltage (D1) Diode, High Voltage (D2) EMI Filter (P/N 100542 USA, UK, Ireland, Brazil, Japan 1Ph) EMI Filter (P/N 100545 Europe, Asia, Pacific, Aust
54 I/O BOARD SCHEMATIC FIGURE 40: I/O Control Board and Test Point Locations
NGC (US) SCHEMATIC 55 NOTES: 1.
NGC (UK) SCHEMATIC 57 NOTES: 1. SCHEMATIC SHOWS OVEN WITH DOOR OPEN AND WITHOUT POWER APPLIED DRAWING OF 40-PIN CONNECTOR OR-9 BK-32 WH-31 BK-25 RD-24 G REEN M3 WHITE M2 RED M1 BLK 4 3 2 1 BL 33 240 VAC 3 PHASE OUT SPD C MD 0-10V I/O C OMMON EN ABLE I/O COM STATU S OK 1 2 3 4 5 6 MAG CT 5 T2 1 M2HV NO C M1HV B L M2FC N G NO NC T1 2 4 -V BK-20 24VDC POWER SUPPLY M1FC C2 C NC M2CD (-) 1 3 4 M1CD (+) (+) (-) D2 2 FT2 1 .13 uF 1 .15 uF 1 3 6 D1 4 A C1 1 .
NGC (EW) SCHEMATIC 59 NOTES: 1.
NGC (ED) SCHEMATIC 61 NOTES: 1.
FIGURE NGC (BRAZIL) SCHEMATIC 63 45: NGC Brazil (Tornado) Schematic
Service Parts and Illustrations
SERVICE PARTS AND ILLUSTRATIONS FIGURE 7: NGC (TORNADO) CONTROL SYSTEM Chapter 4: The Control System - Page 13 +24VDC L K2 MECH RELAY K3 MECH RELAY + 24 VDC - + 24 VDC - + 24 VDC - (U.S.
66 SERVICE PARTS AND ILLUSTRATIONS FIGURE 17: CONTROL SYSTEM PANEL ENCLOSURE AND PARTS Chapter 4: The Control System - Page 20 6 1 5 7 4 8 10 2 9 3 CONTROL SYSTEM PANEL PARTS Figure 17. 1. NGC-1040 NGC-1209 2. 102960 3. 100508 (Varies)* 4. NGC-3023 5. 101954 Cover, Keypad/Display, Std Cover, Keypad/Display, SBK Nut, 4-40, Stainless Smart Card, Blank Smart Card, Programmed* Display Svc Kit (includes Items 5, 6, and 7) Spacer, 1/2” Lg, Aluminum 6. 100193 7. 100184 8.
SERVICE PARTS AND ILLUSTRATIONS 67 FIGURE 18: MONITOR CIRCUIT - SHOWN IN FAILSAFE STATE Chapter 5: The Microwave System - Page 25 LINE VOLTAGE (L1) K2 HV RELAY F3 FUSE 20 AMP (BLOWN) 7 9 A +24 VDC 1 4 3 6 NC CONTROL 2 B 7 A 1 4 3 6 1 NO NC T2 HV TRANSFORMER 9 +24 VDC 3 1 K3 MONITOR RELAY LINE VOLTAGE (L2) PRIMARY AND SECONDARY INTERLOCKS (CLOSED) T1 HV TRANSFORMER CONTROL 3 CDS C CDP C NO 2 MONITOR SWITCH (OPEN) B CONTROL NC CDM C NO FIGURE 20: MICROWAVE SYSTEM PARTS C
68 SERVICE PARTS AND ILLUSTRATIONS FILAMENT AND HIGH VOLTAGE TERMINALS FIGURE 21: MICROWAVE SYSTEM PARTS Chapter 5: The Microwave System - Page 27 25 Microwave System Parts 24. 100186 25. NGC-3015 26. 102070 27. NGC-1163 28.
SERVICE PARTS AND ILLUSTRATIONS 69 FIGURE 24 & 25: HIGH VOLTAGE DIODE AND MAGNETRON Chapter 5: The Microwave System - Page 32 FA F FILAMENT AND HIGH VOLTAGE TERMINALS ANTENNA FIGURE 26: OVEN DOOR REMOVAL AND PARTS 41 Chapter 6: The Oven Door - Page 37 Cook Door Parts 40 38. 102809 39. NGC-3067 39 #8-32 x 3/8” PFH CSK Assy, Oven Door (Traditional) NGC-3067-2 Assy, Oven Door (SBK) 40. NGC-1061 Hinge Block 41. 102804 Right Hinge 42. 102805 Left Hinge 43. 101381 #10-32 x 1/2” Hex SS 44.
70 SERVICE PARTS AND ILLUSTRATIONS FIGURE 29: PRIMARY AND SECONDARY INTERLOCKS ADJUSTMENT AND PARTS - OLD SWITCH SETUP Chapter 6: The Oven Door - Page 40 50 49 APPLY HI-TEMP GREASE TO AREA 48 Primary and Secondary Interlock Switch Parts 47. NGC-1076-2 48. 102809 49. 102921 50. 101557 51. 102012 52. NGC-3033 Actuator, Door Screw, #8-32 x 3/8” 100Þ CSK Screw, #8-32 x 3/8” Screw, #4-40 x 1 1/4” Interlock Switches Assy, Door Switch* 47 51 *See Figure 32 for Assy Detail.
SERVICE PARTS AND ILLUSTRATIONS FIGURE 31: MONITOR SWITCH ADJUSTMENT AND ASSEMBLY - OLD SWITCH SETUP 64 Chapter 6: The Oven Door - Page 41 68 65 66 x2 69 68 67 67 REF 68 Monitor Safety Switch Parts 64. 102804 65. 102012 66. NGC-1126 67. 101912 68. 102921 69.
72 SERVICE PARTS AND ILLUSTRATIONS FIGURES 33 AND 34: SECONDARY AND MONITOR SWITCH ADJUSTMENT AND ASSEMBLY - NEW SWITCH SETUP Chapter 6: The Oven Door - Page 43 78 x2 82 79 83 x2 81 80 81 82 Secondary and Monitor Safety Switch Parts 77. 102804 78. 102012 79. NGC-1126 80. 101914 81. 101915 82. 102921 83. 101558 Hinge, Right Switch, Limit, Micro (x2) Plate, Door Switch Standoff, #8-32 F/F x 1”, 5/16” DIA Standoff, #8-32 M/F x 5/16”, 1/4” DIA (attached to outside of Item 80.
84. NGC-3067* NGC-3067-2* 85. NGC-3021 86. NGC-1061 87. 102750 NGC-1216 88. NGC-1076-2 89. NGC-1132 90. 102945 91. NGC-1138 92. 102809 93. NGC-1165 94. NGC-1125-1 NGC-1125-2 Door, NGC, Generic* Door, NGC, SBK* Kit, Shunt Plate Hinge Block Handle, Door, Generic Handle, Door, SBK Actuator, Door Shim, Door Latch Bolt, 1/4”-20 x 1.00 Label, Precaution #8-32 x 3/8” CSK 100° Label, Caution Empty Door Insulation 1 Door Insulation 2 * Includes items 85 - 101. 97. 101688 98. 102698 99. NGC-1155 100. 101293 101.
SERVICE PARTS AND ILLUSTRATIONS FIGURE 37: CONVECTION CIRCUIT BLOCK DIAGRAM Chapter 7: Convection Circuit - Page 47 BOTTOM IR CONTROL MAIN HX CONTROL +24 WH-28 OT1 - HI-LIMIT MANUAL RESET WH-30 B2 K5 K4 C 32 NC 31 OR540 C 22 NC 21 BL510 C 12 NC 11 RD-19 SSR HT520 MOTOR SPINS COUNTER-CLOCKWISE FROM BACK BL500 BR600 2 L2 L1 M4 GREEN M3 WHITE M2 RED M1 BLACK 4 3 2 1 240 VAC 3 PHASE OUT BMSC SPD CMD BLWR MTR 1 A2 B1 A1 BL530 74 3 2 1 200-240 VAC IN 0-10V I/O COM ENABLE I/O
SERVICE PARTS AND ILLUSTRATIONS 75 FIGURE 38: CONVECTION CIRCUIT ASSEMBLY AND PARTS Chapter 7: Convection Circuit - Page 48 109 x10 110 This Ope device ratio 1. This n complies is 2. This devi subject with device may to thePart 18 of rece ce mus not caus followingthe ived FCC und , inclut acce e harm cond Rule This esired ding pt any ful ope inte inte inte itions: s. DHHOven ratio rfere rfere rfere S Fedecomplies n. nce nce nce.
76 SERVICE PARTS AND ILLUSTRATIONS FIGURE 39: IR ELEMENT AND CATALYTIC CONVERTER PARTS AND ASSEMBLY Chapter 8: IR Element and Catalytic Converter - Page 52 122 119 118 x4 120 119 122 118 117 116 121 IR Element and Catalytic Converter Parts 116. 101312 117. 102449 118. NGC-3003 119. NGC-1116 120. 101688 Snap Ring Washer, Shim IR Element Shield, Microwave Screw, #8 x 1/2” Sht Metal PTH 121. NGC-1030 Clip, Catalytic Converter (Non-SBK) NGC-1233 Clip, Catalytic Converter (SBK) 122.
SERVICE PARTS AND ILLUSTRATIONS FIGURE 46: COVERS AND MISCELLANEOUS PARTS - NON-SBK OVENS 129 130 x2 132 x2 140 128 144 136 131 x3 per panel prise choc a une le a terre. ent e contre miseez seulem continu ement branch ion only. correct ue protect al outlets electriq ed electric assurer Pour against ly ground ion proper t to ed protect 0. connec 1030.1 continu CFR shock, rd 21 s of To provide section Standa ble ance cause applica may l Perform that es with Federa ence ence ence. compli on.
SERVICE PARTS AND ILLUSTRATIONS FIGURE 47: COVERS AND MISCELLANEOUS PARTS - SBK OVENS 147 148 x2 150 x2 158 146 162 149 x3 per panel 154 prise choc a une le a terre. ent e contre miseez seulem continu ement branch ion only. correct ue protect al outlets electriq ed electric assurer Pour against ly ground ion proper t to ed protect 0. connec 1030.1 continu CFR rd 21 s of section Standa ble ance cause applica may l Perform that es with Federa ence ence ence. compli on.
Comprehensive Part List
COMPREHENSIVE PART LIST ITEM DESCRIPTION Actuator, Door Assembly, Keypad/Housing, Cover, Standard Assembly, Keypad/Housing, Cover, SWY Assembly, Keypad/Housing, Cover, SBK Bearings, Bronze, 3/16 ID x 5/16 OD x 1/4 Block, Hinge Block, Sealing, Blower Motor Blower Motor Bolt, 1/4-20 x 1.00 Bracket, Stacking Cable, Ribbon, 26-Pin Cable, Smart Card Reader Cable, VF Display, 3-Pin Cap, Hole, Door Capacitor, HV (Europe, Asia-Pacific) Capacitor, HV (Japan) Capacitor, HV (USA, Latin America, S.
80 COMPREHENSIVE PART LIST ITEM DESCRIPTION Fan Blade, Motor Fan, Magnetron Cooling Filter, EMI, 1Ph (USA, Europe, Latin America, Japan) Filter, EMI, 3Ph (Europe, Asia-Pacific, Korea, Japan) Fuse, F1, 12 Amp Fuse, F2, 12 Amp Fuse, F3, 20 Amp Gasket, Convection Heater Gauge, Door Switch (Adjustment Tool) Grease, Food Grade, USDA H-1 Guard, TurboChef Oven, Domestic Guard, TurboChef Oven, International Handle, Door, Standard Handle, Door, SBK Harness, Line Voltage (Europe, Asia-Pacific, Japan) Harness, Line
COMPREHENSIVE PART LIST ITEM DESCRIPTION Nut, Flange, 1/4-20 Nut, M5, Yellow Zinc (Magnetrons, Bottom Electrical Plate) Nut, Push, 1/8 Nut, Stainless, #4-40 Pad, Abrasive, Non-Slip Pin, Clevis, 3/16 Diameter x 1” Long Plate, Door Switch Plug, Hole, Black, 1/2” Diameter Rack, Raised Rack, Recessed Rack, Standard Reader, Smart Card Relay, K1, Filament Transformers Relay, K2, HV Transformers Relay, K3, Monitor Relay, K4/K5, Solid State, Convection Heater/IR Element Relay, K6, 208/240 Transformer Taps (USA on
82 COMPREHENSIVE PART LIST ITEM DESCRIPTION Shim, 0.030 Shim, 0.045 Shim, Door Latch Shim Tool, 0.030 Shim Tool, 0.
For further information call: 8 0 0 .9 0 T U R B O or +1 214-379-6000 Accelerating the World of Cooking Headquarters Global Operations Six Concourse Parkway Suite 1900 Atlanta, Georgia 30328 678.987.1700 P H O N E 678.987.1750 F A X TURBOCHEF.COM 4240 International Parkway Suite 105 Carrollton, Texas 75007 214.379.6000 P H O N E 214.379.
