Accelerating the World of Cooking TM Service Manual FOR THE TURBOCHEF 2020 HIGH h CONVEYOR OVEN © 2008 TurboChef Technologies, Inc.
For further information, call 800.90TURBO or +1 214.379.
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. Please carefully read this manual and retain it for future reference.
Table of Contents Safety Information Important Safety Information – Please Read First General Safety Information Reducing Fire Risk Preventing Oven Damage Grounding Instructions Power Cord Replacement i i i ii ii ii Specifications and installation Dimensions Electrical Specifications Packaging Certifications Oven Construction Installation Instructions Delivery and Initial Inspection Lifting the Oven Oven Location and Placement Stacking Ovens Installation Near Open Heat Source Ventilation Requirements 1 1
Initiating a Burn-In Test Erasing Oven Settings Viewing the Serial Number 20 20 20 Oven Systems The Control System Control Board Display EMI Filter Fuses High-Limit Thermostat Keypad Power Supply - 24VDC Relays, K6 (Heaters) and K7 (Conveyor Direction) Relay, Solid State - K5/K4 Heaters RTD Smart Card Reader Speaker Thermostats - 120ºF (Close on Rise) Wire Harness The Conveyor System Gear Drive (Conveyor Motor) Gear Drive (Conveyor Motor) Speed Controller (CMSC) The Convection System Blower Motor Blower M
i Important Safety Information – Please Read First Improper installation, adjustment, alteration, service, or maintenance of this equipment can cause property damage, injury, or death. Thoroughly read the installation, operating, and maintenance instructions before installing or servicing this equipment.
ii S A F E T Y I N F O R MAT I O N Preventing Oven Damage o o o x o x o When servicing this appliance, do not tear insulation to get to components. Rather, find the edge of the insulation and remove the tape that holds it in place. Clean the oven daily. Clean the oven only with TurboChef Oven Cleaner. DO NOT clean with a water jet. DO NOT allow cleaning solution or water to remain in the cook cavity longer than necessary.
Specifications and Installation
1 Dimensions Exterior 8.5” (216 mm) Height --with legs 35.7” (907 mm) 13.0” (330 mm) 17.0” (432 mm) Width 48.3” (1227 mm) --with extensions 60.1” (1527 mm) 35.7” (907 mm) Depth Figure 1: Oven Dimensions - Side 60.1” (1527 mm) with extensions Conveyor Length 48.3” (1227 mm) Width (Single) Width (50/50) Width (70/30) 20.0” (508 mm) 9.5” / 9.5” (241 mm / 241 mm) 15” / 4” (381 mm / 102 mm) Figure 2: Oven Dimensions - Top Electrical Specifications 48.3” (1227 mm) 17.0” (432 mm) 13.0” (330 mm) 4.
2 S P E C I F I C AT I O N S A N D I N S TA L L AT I O N Packaging All ovens are packaged in a double-wall corrugated box with integrated wooden skids. All international ovens shipped via Air or Less than Container Loads are packaged in wooden crates.
3 The surface on which the oven is placed must be at least 30” (762 mm) deep and capable of supporting 200 lbs. (90.7 kg) per oven. The manufacturer shall not assume liability for damage or injury resulting from the improper installation of this equipment, including temporary or unstable work stations or countertops. The oven must be installed level front to back and side to side. For additional stability, the oven legs may be bolted to the countertop if desired.
4 S P E C I F I C AT I O N S A N D I N S TA L L AT I O N Installation Near Open Heat Source Ventilation Requirements See Figure 7. When placing a TurboChef oven near an open heat source, strictly adhere to the following: The HhC2020 should be operated underneath a ventilation hood, except where local laws or codes allow for use without a ventilation hood. For more information or to order a ventilation hood, contact 800.90TURBO, +1 214-379-6000, or your local distributor.
Cleaning - Daily and Weekly
5 Daily Cleaning Instructions = Wash, rinse, sanitize. (Use only TurboChefapproved cleaner, part number 103180). = Completely dry with clean towel. WARNING: Always disconnect power before cleaning or servicing the oven. WARNING: DO NOT attempt to clean the oven until it has cooled (screen reads “Oven Off ”). WARNING: DO NOT use a water jet when cleaning the oven.
CLEANING Weekly Cleaning Instructions = Wash, rinse, sanitize. (Use only TurboChef-approved cleaner, part number 103180). = Completely dry with clean towel. WARNING: Always disconnect power before cleaning or servicing the oven. WARNING: DO NOT attempt to clean the oven until it has cooled (screen reads “Oven Off ”). WARNING: DO NOT use a water jet when cleaning the oven. Step 1: Turn the Oven Off 1.
7 Step 4: Clean Oven Components Step 3: Remove Inner Oven Components 1. 1. 2 1 2. 2. 1 2 1 3. 3. 4. 4. Replace filters if damaged or torn. 2 1 5. 1 5. 6. 7.
8 CLEANING Replace Oven Step 5: Reinstall Oven Components 9. 1. 2. 2 2 1 Step 6: Verify Chain Tension 3. See detail below. A B 4. Acceptable - Chain (A) is tight and easily clears crumb tray holder (B) 2 1 A B 5. Call service to have link removed - Chain (A) is loose and risks contact with crumb tray holder (B) Step 7: Ready the Oven for Use 6. 7. 8. Latch 1. 2.
Standard Oven Operation
9 2 2 High h Conveyor by TurboChef TM BACK OFF IDLE 5 GE ER Y NC EM 3 4 S 6 TOP 1 Figure 8: Oven Controls Oven Controls Oven Controls Figure 8. Figure 19 1. Display 4. Back/Off Key The display shows current oven operation and/or user programming information. Depending on the mode the oven is in, the back/off key will return the oven to the previous screen or turn the oven off (page 10). 2.
10 S TA N DA R D O V E N O P E R AT I O N 1 4 BREAKFAST DINNER 6 BREAKFAST OVEN OFF BELT F 5:00 DESSERT LUNCH 2 SOAKING TIME LEFT = 5:00 BELT R 3:20 BTM AIR 100 % BREAKFAST TOP AIR 80 % BELT SPEED 2:00 3:00 LUNCH 2:30 2:45 DESSERT DINNER COOLING DOWN SET 475F 5 DINNER 2:00 4:00 BREAKFAST 5:00 3:20 BREAKFAST TOP AIR 80 % OVEN TCC = 425F LUNCH DESSERT 7 BELT F 5:00 COOKING BELT R 3:20 BREAKFAST SET 475F BELT F 5:00 BTM AIR 100 % BELT R 3:20 TOP AIR 30% OVEN IDLE PRESS ANY KE
11 Mode 3: Warming Mode 6: Cooling Down Mode during which the oven warms to the preset cooking temperature defined by the cooking profile that was selected. Mode during which the heater shuts off to allow the oven to cool. Happens When... - A selection is made from MODE 2, and the oven’s temperature at the beginning of warmup was not within (less than) 25°F (14°C) of the oven’s set temperature. Goes To... - MODE 4 once the oven has reached the temperature defined by the selected cooking profile.
12 S TA N DA R D O V E N O P E R AT I O N Editing a Cooking Profile Changing a Cooking Profile Name To edit a cooking profile, the oven must be in the COOKING MODE, and the full edit or flex option must be enabled for each option you want to edit. For more information on selecting between full edit, rigid, and flex options for each editable setting, see Edit Modes Select Screen on page 16. 1. From the cooking screen (Figure 10), press L1 to access the name change screen (Figure 11).
13 Adjusting the Belt Speed PROFILE 1 TOP AIR 80 % The High h Conveyor Oven can accommodate R BELTconveyor either one or two belts. The oven will 10:00 automatically detect the number of conveyor belts installed and display the option to change the speed of each conveyor belt independently. 1. From Figure 10, press the soft key adjacent to the conveyor belt you wish to adjust (press L2 for the front belt [Belt F] or L3 for the rear belt [Belt R]). 2.
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Oven Modes
15 Config Mode Accessing the Fault Count Screen The CONFIG MODE (Figure 12) serves four main purposes: 1. To access the smart card screen. 2. To access the fault count screen. 3. To access the SETUP MODE. 4. To access the TEST MODE (service use only). From the CONFIG MODE (Figure 12), press R1 to access the fault counts screen (Figure 16, page 16). The oven will display the number of faults that have occurred. To access the CONFIG MODE, press the up key from the OVEN OFF MODE.
16 OVEN MODES Changing the Display Temperature Info Screen The oven can display the temperature in either Celsius or Fahrenheit units. To change the display temperature, press L1 in SETUP MODE (Figure 17).
17 NOTE: If the update is unsuccessful, the display will remain off and the oven will beep one long, low tone. If this occurs, repeat the above procedure. If the update fails multiple times, a smart card may be damaged. Please note that the oven will be inoperable until a successful update is performed. As such, TurboChef reinforces proper handling of smart cards to help prevent static damage, and recommends that each service technician keep a backup copy.
18 OVEN MODES Accessing the Belt Control Screen Top Display Line From TEST MODE screen 1 (Figure 21, page 17), press L2 to access the belt control screen (Figure 25). Use this mode to verify the belts work correctly. The number after the belt speed shows the pulses read by the HES. The percentage is the amount of drive being asked of the CMSC (100% = 10V). The top display line shows values relating to oven components.
19 Bottom Display Line Entering a New Serial Number The bottom display line shows enabled inputs and outputs on the control board. The numbers 1-10 indicate the different bottom display line, which are explained below. Figure 27 1. Press L1 (Figure 22, page 17) on screen 2 of the TEST MODE to access the serial number input screen. NOTE: A “-” or “_” displayed on the bottom display line denotes values that are in the off mode or closed. 2. Enter the new serial number.
20 OVEN MODES Initiating a Burn-In Test Viewing the Serial Number NOTE: Burn-in tests are for manufacturing use only. DO NOT initiate a burn-in test unless expressly instructed by TurboChef. The serial number is located at the bottom of screen 2 of the TEST MODE (Figure 22, page 17). To initiate a burn-in test, Press L2 (Figure 22, page 17) on screen 2 of the TEST MODE. The burn-in test (Figure 28) runs the oven for 45 minutes to ensure correct oven operation.
Oven Systems
21 The Control System Fuses This section contains information about the following components: - Control Board - Display - EMI Filter - Fuses - High-limit Thermostat - Keypad - Power Supply, 24VDC - Relay (K6 - Heaters) - Relay (K7 - Conveyor Direction) - Relay, Solid State - RTD - Smart Card Reader - Speaker - Thermostats - 120ºF (Close on Rise) - Wire Harness The control circuit is ultimately protected by two 20-amp class CC fuses, which are in the linevoltage circuit (incoming voltage).
22 O V E N S YS T E M S 1. Disconnect line voltage to the unit. 2. Place the RTD in a bowl of ice water for 2 minutes. 2. Take a resistance reading of the coil. 3. Take a resistance reading of the RTD. Testing Procedure 3. If coil resistance is correct (585 W): a) Apply line voltage to the unit. b) Check for 24 VDC at the coil of the relay when the unit is calling for heat. c) Check the state of the contacts.
23 The Conveyor System This section contains information about the following components, as well as testing procedures: - Gear Drive (Conveyor Motor) - Gear Drive (Conveyor Motor) Speed Controller (CMSC) Gear Drive (Conveyor Motor) The conveyor motor is a 1610 RPM, 3-phase motor with a built-in Hall Effect Sensor. The speed of the conveyor motor is controlled by the voltage frequency applied to the windings from the CMSC.
24 O V E N S YS T E M S Accessing Parameters WARNING: DO NOT perform this procedure unless instructed by TurboChef. Changing the parameters to other than those preset by TurboChef can damage critical oven components. NOTE: “Motor Rated Speed” (07) is RPM of motor before gearbox, not after. 1. Open the right end bell (page A-8). 2. Locate the CMSC (page A-8). 3. Press the M key. 4. Use the and keys to navigate the parameters. See page 40. 5.
Troubleshooting
25 Overview of Troubleshooting F5: CC Over Temp This section contains information on the following: - Fault code descriptions - Fault code troubleshooting - Non-fault code troubleshooting This fault is displayed if the cook cavity’s temperature reaches or exceeds 625°F (329.4°C). Fault Code Descriptions Fault codes are logged in a fault counter (page 15) for troubleshooting.
26 T R O U B L E S H O OT I N G Fault Code and Description When Active Warming F1: Blower Failure a Refer to...
27 Fault Code Troubleshooting From TEST MODE, you can test separate oven components to help diagnose an issue. To access TEST see page 17. MODE, Troubleshooting: F1:BLOWER FAULT Access the TEST MODE. (page 17) Are the status indicators at location 7 and 8 present (page 18)? NO 7 YES 8 Is the blower motor spinning freely? Open Left End Bell. Open the Right End Bell.
28 T R O U B L E S H O OT I N G Blower Motor Troubleshooting NOTE: Continued from page 27. 1. Verify motor spins freely. - Motor seized: Unplug oven and correct obstruction or replace motor. - Motor spins freely: Verify motor windings (see Figure 36, page 27). 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 on page 27. If motor is OK, proceed to step 3, below. 3.
29 Troubleshooting: F2: LOW COOK TEMP Restart the oven, access the TEST MODE, and turn on both the top and bottom blowers. Are the status indicators at location 6, 7, 8, and 9 present (pages 18-19)? NO Troubleshoot the blowers (pages 27-28). YES Are the nozzles and plenums correctly installed? NO Correctly reinstall the nozzles and plenums. NO Replace element(s). YES Are all elements heating (ensure amp draw is correct page 24)? YES Open the right end bell.
30 T R O U B L E S H O OT I N G Troubleshooting: F5: CC OVER TEMP Is an F1 fault present? YES Troubleshoot F1 fault (pages 27-28). NO Is anything obstructing regular airflow into the cook chamber? YES Remove the obstruction. NO Place the oven in TEST MODE and test the heaters (page 17). Do measurements show the heaters are ok (page 24)? NO Replace the defective heater(s). YES Is the solid state relay functioning properly? NO Replace the SSR (page A-7).
31 Troubleshooting: F6: EC OVER TEMP Are the air filters on the back of the oven clean? NO Clean the air filter(s) (page 7). YES YES Access TEST (page 17). Is the status indicator at position “b” (page 18) less than 65? MODE Is the oven hot? NO YES NO Open the left and right end bells. Are the cooling fans running? Replace the I/O control board (page A-8). YES NO Check for -Dirt or debris in the cooling fan blades. -A heat source near the filter.
32 T R O U B L E S H O OT I N G Troubleshooting: F7: RTD FAULT Is the RTD connected properly to the I/O control board (pages 37-40)? Open the right end bell. Replace the RTD (page A-8). YES YES Is the RTD damaged or defective (page 22)? NO Is the RTD open? Using an ohmmeter, measure at the control board (pages 3740). RTD should measure approximately 100 W at 32°F (0°C) See page 22 for ohm/temperature chart. NO Correct wiring (pages 37-40). YES NO Replace the I/O control board (page A-8).
33 Troubleshooting: F9: BELT FAULT (Total Belt Run Failure) Are there any obstructions that are blocking the conveyor’s movement or is the conveyor belt damaged? YES Remove obstruction or replace/repair the conveyor and restart the oven. Is the F9 fault code still present? NO Remove the chain guard (page A-4). Is the chain damaged or obstructed in any way? YES NO YES Correct wiring (pages 37-40). NO Open the right end bell (also open the left end bell if split belt conveyor).
34 T R O U B L E S H O OT I N G Non-Fault Code Troubleshooting This section provides troubleshooting tips for issues that may occur independently of an oven fault. Troubleshooting: Cooling System Issue Is the oven in an area of moderate temperature (120ºF [49ºC] or cooler)? NO YES Does the oven have room to ventilate (not tightly enclosed by other appliances or fixtures)? Relocate oven to cooler area. NO Move oven to open area or remove items that are in close proximity.
35 Troubleshooting: Food Not Cooking Properly Does the problem occur for all programmed recipes? For example, are all recipes undercooked/overcooked/etc.? NO YES Are there any fault codes present (page 25)? YES Is the food item in the correct starting state (e.g., frozen, fresh, etc.)? NO NO Troubleshoot the fault(s) using the steps on pages 27-33.
36 T R O U B L E S H O OT I N G Troubleshooting: No Display - Screen is Blank Does the keypad beep when a key is pressed? YES NO Replace the fuses (page A-7). Is wiring from the control board to the display (including the ribbon cable) OK? NO Is the 24 VDC power supply receiving power? Correct wiring. If cable is damaged, replace it. Replace the power supply (page A-8).
Schematics
37 (HHC-6630-2) (HHC-4120) (102075) (TC3-0433) (CON-7002) BACK HCT-4161 208 VAC (HHC-6630-2) FRONT HCT-4162 208 VAC (HHC-4120) (NGC-3005) (NGC-3023) (HHC-6517-2) S C H E MAT I C S
S C H E MAT I C S 8 5 4 DWG NO 3 NOTES: LTR COLOR CODE (LINE VOLTAGE) BL - BLUE = LINE V (208/240) BR - BROWN = LINE V (208/240) A 6 2 8 4 7 3 1 0 (101279) - - - - - 14 - - - - - 14 C-13 (WHT) 8 0 B-18 (RED) 1 J6 P6 4 DATE APPROVED JKP PRODUCTION RELEASE RL2 BMSC (100443) 240 VAC 3 PHASE OUT J2 1 2 180-240 3 VAC IN L1L2 U V W PE 6 3 J5 1 2 3 4 (HCT-4205) 7 Analog Speed 0-10V I/O COMMON ENABLE I/O COM STATUS OK I/O COMMON 1 2 3 4 5 6 A-17 (RED) B-6 (BLACK) B-2 (WHIT
39 S C H E MAT I C S
40 S C H E MAT I C S CMSC PARAMETERS
Appendix - Replacing Oven Components
A- 1 Replacing Oven Components WARNING: Before removing or replacing any oven component, thoroughly read the safety instructions found at the front of this manual and Oven Systems (pages 21-24). Adhere to all precautions and warnings outlined in these sections, as failure to do so could result in serious injury or death. Part Details... Locate the Part Here... Outside of Left End Bell Qty.
A- 2 A P P E N D I X - R E P L AC I N G O V E N CO M P O N E N TS Locate the Part Here... Part Details... Outside of Qty.
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A- 4 A P P E N D I X - R E P L AC I N G O V E N CO M P O N E N TS Replacing Items - Outside of End Bells WARNING: Before removing or replacing any oven component, thoroughly read the safety instructions found at the front of this manual and Oven Systems (pages 21-24). Adhere to all precautions and warnings outlined in these sections, as failure to do so could result in serious injury or death.
A- 5 Part Number Hardware Description Hardware Part Number(s) Air Filter HCT-4067 None None Back Panel HCT-4105 Screw, #10-32 x .
A- 6 A P P E N D I X - R E P L AC I N G O V E N CO M P O N E N TS Replacing Items - Left End Bell WARNING: Before removing or replacing any oven component, thoroughly read the safety instructions found at the front of this manual and Oven Systems (pages 21-24). Adhere to all precautions and warnings outlined in these sections, as failure to do so could result in serious injury or death.
A- 7 Part Number Hardware Description Hardware Part Number(s) Blower Motor Assembly HCT-4205 Nut, 1/4-20, Serrated HEX Flange, Plated Steel Screw, #10-32 x 5/8, SKT HD, PLT Standoff, #10-32 x I, F/F, 3/8 HEX, PLT Spacer, #10 (.
A- 8 A P P E N D I X - R E P L AC I N G O V E N CO M P O N E N TS Replacing Items - Right End Bell WARNING: Before removing or replacing any oven component, thoroughly read the safety instructions found at the front of this manual and Oven Systems (pages 21-24). Adhere to all precautions and warnings outlined in these sections, as failure to do so could result in serious injury or death.
A- 9 Hardware Description Hardware Part Number(s) Blower Motor Assembly HCT-4205 Nut, 1/4-20, Serrated HEX Flange, Plated Steel Screw, #10-32 x 5/8, SKT HD, PLT Standoff, #10-32 x I, F/F, 3/8 HEX, PLT Spacer, #10 (.
For service or information: W I T H I N N O RT H A M E R I C A C A L L Customer Service at 800.90 T U R B O or 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 TM Part Number: HCT-4202/Revision B/July 2008 Country Code: NA/EU Corporate Headquarters Global Operations Six Concourse Pkwy, Suite 1 9 0 0 Atlanta, Georgia 3 0 3 2 8 U S A +1 678.987.1700 PHONE + 1 6 7 8 . 9 8 7 .
